Publications

Researchers at Plasma Processes Inc. have produced a Functional Gradient Material (FGM) through advanced vacuum plasma spray processing for high heat flux applications. Outlined in this paper are the manufacturing methods used to develop a four component functional gradient material of copper, tungsten, boron, and boron nitride. The FGM was formed with continuous gradients and integral cooling channels eliminating bondlines and providing direct heat transfer from the high temperature exposed surface to a cooling medium. Metallurgical and x-ray diffraction analyses of the materials formed through innovative VPS (vacuum plasma spray) processing are also presented. Applications for this functional gradient structural material range from fusion reactor plasma facing components to missile nose cones to boilers.

Beryllium because of its low atomic number and high thermal conductivity, is a candidate for both ITER first wall and divertor surfaces. This study addresses the following: why beryllium; design requirements for the ITER divertor; beryllium supply and unirradiated physical/mechanical property database; effects of irradiation on beryllium properties; tritium issues; beryllium health and safety; beryllium-coolant interactions and safety; thermal and mechanical tests; plasma erosion of beryllium; recommended beryllium grades for ITER plasma facing components; proposed manufacturing methods to produce beryllium parts for ITER; emerging beryllium materials; proposed inspection and maintenance techniques for beryllium components and coatings; time table and costs; and the importance of integrating materials and manufacturing personnel with designers.

The durability of a carbon-carbon composite, Aerolor A05, X-point divertor dump plate to thermal fatigue was evaluated for the Joint European Torus (JET) at Sandia's Plasma Material Test Facility. Of primary interest was the effect of thermal cycling on the carbon-carbon threads of the bolted attachment scheme for the Aerolor X-point divertor. This report describes the testing performed at the Ion Beam Test System and the test and analysis results obtained in support of this effort. After completing 1000 thermal cycles, where the surface temperature of the 8 cm by 8 cm by 2.3 cm Aerolor tile reached 2200{degree}C during a 10 s, 500 W/cm{sup 2} pulse, the tile survived without any noticeable damage. Post test inspection of the carbon-carbon threads showed only minor wear and no signs of significant damage. Thermal modeling of the test article using the ABAQUS finite element code agreed very well with experimental results. The thermal creep experienced by the M-12 stainless steel bolt during ion beam testing will not be expected to occur during normal operations in JET because of the longer cycle times between the thermal events. Finite element analysis indicates that the longer cycle times at the JET will reduce the peak temperatures in the vicinity of the bolt and bolt insert below the level at which thermal creep would occur. An additional margin of safety could be obtained by using Inconel or Nimonic fasteners. Overall, the performance of the bolted divertor design to thermal fatigue was acceptable. 12 figs., 2 tabs.