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FUSION TECHNOLOGY

Annual Report of the Association EURATOM-CEA

2004 (full report)

Compiled by : Ph. MAGAUD and F. LE VAGUERES

ASSOCIATION EURATOM-CEA DSM/DRFC

CEA CADARACHE 13108 Saint-Paul-Lez-Durance (France)

Tél. : 33 - 4 42 25 46 59 Fax : 33 - 4 42 25 64 21 e-mail : dirdrfc@drfc.cad.cea.fr Web : http://www-fusion-magnetique.cea.fr

This report is also available on-line at : http://www-fusion-magnetique.cea.fr

Cover : The Articulated Inspection Arm (AIA), an articulated multipurpose tool to demonstrate the feasibility of close inspection of the ITER Divertor cassettes and Vacuum Vessel first wall. The AIA is able to operate under temperature

(120°C) and vacuum (10-6 Pa).

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CONTENTS

INTRODUCTION ................................................................................................................................ 1

EFDA TECHNOLOGY PROGRAMME ........................................................................ 3

Physics Integration Plasma Edge TW3-TPP-ERDIAG Evaluation of Laser Ablation Optical Emission Spectroscopy (LA-OES) method for graphite co-deposited layer characterization ....................................... 5 Heating and Current Drive CEFDA01-645 TW2-TPHN-NBDES1: Support to neutral beam physics and testing 1 ................ 9 CEFDA03-1129 TW3-TPHI-ICRDES1: ITER ICRF Antenna and matching system design .......... 13 Diagnostics CEFDA02-1003 TW2-TPDS-DIASUP4 and TW3-TPDS-DIASUP1: CEFDA03-1111 Support to the ITER diagnostic design .................................................................. 17 TW2-TPDS-DIADEV-D02 Development of diagnostic components - First mirror study ................................. 19

Vessel-In Vessel Vessel-Blanket and Materials CEFDA03-1067 TW3-TVM-MDB: Rules for design, fabrication and inspection Establishment and Operation of a Material Database ............................................ 23 CEFDA03-1091 TW4-TVM-LIP: Rules for design, fabrication and inspection

Modification of ITER materials documents and assessment of material data for licensing TBM’s design rules ................................................. 25

TW0-T508/05 Development of Be/CuCrZr brazing techniques .................................................... 27 TW1-TVV-HIP Improvement of HIP Fabrication techniques ......................................................... 31 TW2-TVV-ROBOT Dynamic test rig for Intersector Welding Robot (IWR) for VV sector field joining ..................................................................................... 33 TW3-TVM-JOINT Characterization of the CuCrZr/SS junction strength for different blanket manufacturing conditions ..................................................... 35 TW3-TVV-DISFREE Further development of the hybrid MIG/Laser welding technique for VV sector field joining ..................................................................................... 39

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TW3-TVV-ROBASS Long detection range seam tracker ........................................................................ 43 TW4-TVV-OSWELD Qualification of multiple phased array UT for one sided welds during VV manufacture ......................................................................................... 45 Plasma Facing Components CEFDA01-585 TW1-TVP-TESTAN: Monitoring and analysis of thermal fatigue testing of divertor prototypes - 200 kW electron beam gun test ........................................ 49 CEFDA02-583 TW1-TVV-DES: Destructive examination of primary first wall panels and mock-ups ......................................................................................................... 55 CEFDA03-1029 TW3-TVB-JOINOP: Optimization of Be/Cu alloy joints for primary first wall panels .................................................................................. 59 CEFDA03-1051 TW4-TVD-ACCEPT: Study on acceptance criteria for the ITER divertor vertical target ...................................................................... 63 CEFDA03-1077 TW3-TVB-INMOCK: Fabrication of primary first wall mock-ups for in-pile experiments ........................................................................................... 67 TW0-T438-01 Development and testing of time resolved erosion detecting techniques .............. 71 Remote Handling TW4-TVR-AIA Articulated Inspection Arm (AIA) ......................................................................... 73 TW4-TVR-Radtol Radiation tolerance assessment of standard electronic components for remote handling ............................................................................................... 77 TW4-TVR-WHMAN Development of a water hydraulic manipulator ..................................................... 83

Magnet Structure CEFDA03-1015 TW2-TMSM-COOLINL: Mock-ups for the TF and CS Terminal regions and Cooling Inlets .................................................................................................. 87 CEFDA03-1120 TW3-TMSC-ASTEST: Tests of advanced Nb3Sn strands Extensive characterization of industrial advanced Nb3Sn strands developed for ITER TF coils system ..................................................................... 91 CEFDA04-1127 TW4-TMSC-SAMAN1: Manufacture of sub-size samples ................................... 93 CEFDA04-1134 TW4-TMSC-BARBEN: Bending strain effects of single strands Study of bending strain effect on critical properties of Nb3Sn strands jacketed with stainless steel for various bending amplitudes and temperatures .... 95 TW1-TMC-CODES Design and Interpretation Codes Determination of thermohydraulic properties of cable-in-conduit conductors with a central channel ............................................................................................ 99 TW1-TMS-PFCITE Poloidal Field Conductor Insert (PFCI) ................................................................. 103 TW2-TMST-TOSKA TFMC testing with the LCT coil ........................................................................... 105 TW3-TMSC-ELRES Experimental assessment of the effect of electrical resistances on the V-I characteristics of superconductive cables ............................................. 109

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Tritium Breeding and Materials Breeding Blanket Helium Cooled Pebble Bed (HCPB) blanket TW2-TTBB-002b-D01 Blanket manufacturing techniques - First wall HIPping with open channels ........ 113 TW4-TTBB-005-D01 HCPB breeder and neutrons multiplier materials Procurement and quality control of Li2TiO3 pebbles ............................................. 115 Helium Cooled Lithium Lead (HCLL) blanket TW2-TTBC-001-D01 Helium Cooled Lithium Lead - TBM design, integration and analysis Blanket system design and analysis - Integration and testing in ITER .................. 117 TW2-TTBC-002-D01 Blanket manufacturing techniques Fabrication processes for HCLL and HCPB TBMs ............................................... 123 TW2-TTBC-002-D03 Testing of small-scale mocks-ups to qualify manufacturing technologies ............ 127 TW2-TTBC-005-D01 Helium Cooled Lithium Lead - Safety and Licensing Test Blanket Module (TBM) accidental safety study ............................................ 129 TW4-TTBC-001-D01 TBM design, integration and analysis - Testing programme

and engineering design of the first HCLL TBM for ITER H-H phase .................. 133 Structural materials development Reduced Activation Ferritic Martensitic (RAFM) steels TW2-TTMS-001b-D02 Irradiation performance - Neutron irradiation to 70 dpa at 325°C and PIE ........... 135 TW2-TTMS-004a-D04 Eurofer : Fusion welds development - Evaluation of a welding process adapted to the Test Blanket Module’s geometry : Assembly of the horizontal cooling plates with the continuous wave YAG laser welding process .................. 139 TW2-TTMS-004b-D01 Tubing process qualification - Advanced process development and testing for the production of TBM's cooling channels ...................................................... 143 TW2-TTMS-004b-D02 Qualification of fabrication processes - Processing of high quality welds according to TBM design ...................................................................................... 145 TW2-TTMS-005b-D03 Rules for design, fabrication and inspection Fracture Mechanics Assessments of TBM's .......................................................... 151 TW4-TTMS-005-D01 Rules for design, fabrication and inspection Update Data Base and Appendix A of DEMO-SDC ............................................. 155 TW4-TTMS-007-D02 Modelisation of irradiation effects Ab-initio defect energy calculations in the Fe-He system ..................................... 157 Advanced materials TW3-TTMA-001-D04 SiC/SiC ceramic composites - Divertor and Plasma Facing Materials .................. 161 TW3-TTMA-002-D04 TW4-TTMA-001-D04 Modelling of the mechanical behaviour of advanced 3D SiCf/SiC composite ...... 163 Neutron source TW4-TTMI-001-D01 IFMIF accelerator facilities - Accelerator system design ...................................... 167

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Safety and Environment SEA5-1 Validation of computer codes and models ............................................................. 171 TW1-TSW-002 Waste and decommissioning strategy .................................................................... 175 TW3-TSS-SEA5.3 Ice formation on cryogenic surfaces ...................................................................... 181 TW3-TSW-002 Assessment of radioactive waste in ITER hot cell facility .................................... 183 TW4-TSS-SEA5.5-D02&D05 Validation of the PAXITR and PACTITER code against fusion-specific experiments ....................................................................... 187 TW4-TSS-SEA5.5-D11 Validation of the PACTITER code against fusion-specific experiments Development of the PACTITER code ................................................................... 191

System Studies Power Plant Conceptual Studies (PPCS) TW2-TRP-PPCS15-D03 Waste management strategy on mode A and B ..................................................... 193 TW4-TRP-002-D02b Conceptual design of a HCLL reactor - Tritium control & management analysis, thermo-hydraulic and thermo-mechanical analyses ........... 197 TW4-TRP-002-D04 Conceptual design of a HCLL reactor - Design Integration .................................. 201

ITER Site Preparation European ITER Site Studies (EISS) CEFDA03-1069 European ITER Site Studies (EISS) CEFDA03-1082 TW3-TES-EISSg1: EISS 3 generic tasks CEA CEFDA04-1161 TW3-TES-EISS2c: EISS 3 stage 2 TW4-TES-COLABA TW3-TES-EISS4F: European ITER site study 4 – Cadarache TW4-TES-COLABA: Cadarache site for ITER - Collaboration with Local Authorities .................................................................... 207 Site and Plant Layout CEFDA03-1083 TW3-TEP-CRYO2: Design of ITER cryoplant/cryo-distribution system (auxilliary coldboxes, cryoline…) ......................................................................... 211

Design Support and Procurement Design Support CEFDA03-1098 TW3-TDS-MAGCEA: Detailed engineering and manufacturing studies of the ITER magnet system: Poloidal Field (PF) coil windings and cold test assessment ......... 215

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JET Technology Physics Integration Heating Systems CEFDA03-1031 JW3-EP-ICRH and JW4-EP-ICRH: Contribution to ICRH CEFDA04-1146 components antenna limiter ................................................................................... 219 Diagnostics CEFDA03-1044 JW3-EP-IRV: Diagnostics enhancement - Wide angle IR endoscope ................... 221 Vessel-In Vessel Plasma Facing Components JW0-FT-3.1 Internal PFC components behaviour and modelling .............................................. 223 Safety and Environment JW3-FT-2.15-D01 Detritiation of soft housekeeping materials (mainly plastics) ................................ 227 JW3-FT-2.15-D02 Detritiation of vacuum oil and organic liquids ...................................................... 231 JW4-FT-3.19 Laser decontamination/Tritium removal - Studies on Tokamak wall surfaces decontamination by pulsed repetition rate lasers ................................................... 235

Heating Systems Technology Project CEFDA03-1047 TW3-THHN-IITF1: The first ITER NB injector and the ITER NB test facility: design ........................................................................... 239 CEFDA04-1140 TW4-THHN-ADSD2: Neutral beam development for EFDA extension .............. 243 TW3-THHE-CCGDS1 Coaxial cavity gyrotron and test facility - Design, support to the industrial development and preparation of the technical specifications ................................ 247 TW3-THHI-GTFDS1 Fusion diacrode, IC RF generator, IC power supply and IC test facility - Design, support to the industrial development and preparation of the technical specifications ...................................................... 249

UNDERLYING TECHNOLOGY PROGRAMME ................................................ 251

Vessel-In Vessel Plasma Facing Components UT-VIV/PFC-Damage Study of damage mechanisms in plasma facing components ................................ 253 UT-VIV/PFC-HIP Improvement of reliability, performance and industrial relevancy of HIP processes for PFC components .................................................................. 255

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UT-VIV/PFC-NanoSic Nanocrystalline silicon carbide (SiC) Optimization of the preparation of NanoSiC ......................................................... 259 UT-VIV/PFC-Pyro Application of a tricolour pyroreflectometer to plasma facing components in-situ infrared monitoring ..................................................................................... 263 Remote Handling UT-VIV/AM-ECIr Remote handling techniques - Radiation effects on electronic components .......... 267 UT-VIV/AM-Hydro Technologies and control for remote handling systems ......................................... 273 UT-VIV/AM-Vacuum Technologies for vacuum and temperature and magnetic field conditions for remote handling systems .................................................................................. 275

Tritium Breeding and Materials Breeding Blanket UT-TBM/BB-He Helium components technology - Problems and outline of solutions .................... 279 Materials Development Structural Materials UT-TBM/MAT-LAM/Opti Development of new RAFM steels with regard to creep properties ...................... 283 UT-TBM/MAT-Modpulse Pulsed irradiation of the martensitic alloy Eurofer Irradiations by krypton ions at 350 and 550°C at high flux during short time ....... 287

Safety and Environment UT-S&E-LASER/DEC Laser decontamination/Tritium removal – Modelling of lasers surface heating .... 291 UT-S&E-LiPbwater Recalculation of the LIFUS experiment (interaction between lithium-lead and water) with the 3D version of SIMMER ......................................................... 295

APPENDIX 1 : Directions contribution to the fusion programme ........................ 299

APPENDIX 2 : Allocations of tasks .......................................................................................... 303

APPENDIX 3 : Reports and publications .............................................................................. 309

APPENDIX 4 : CEA tasks in alphabetical order .............................................................. 317

APPENDIX 5 : CEA sites ................................................................................................................. 321

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INTRODUCTION

European research on controlled thermonuclear fusion is carried out in an integrated programme with the objective to develop a safe, clean and economically viable energy source. Part of this programme is under the responsibility of the European Fusion Development Agreement (EFDA) which provides a framework covering the activities in the field of technology (both Next Step and Reactor) and the collective use of the Joint European Torus (JET). This annual report summarizes activities performed by the Euratom-CEA Association in 2004 within the frame of the European Technology Programme (both “EFDA” activities and “Underlying Technology” programme). It does not include keep-in touch activities in the frame of Inertial Confinement Energy, reported in a specific issue performed by the European Commission. This full report is also available on line at “http://www-fusion-magnetique.cea.fr“. In each section, the tasks are sorted out according to the EFDA main fields : Physics (TP) , Vessel/In-Vessel (VIV), Magnets (TM), Tritium breeding and Materials (TT), Safety and Environment (TS), System Studies (TS), JET technology activities (TJ),… The Euratom-CEA Association is involved in all these topics (figure 1). Euratom-CEA activities carried out in the field “Physics Integration” are mainly linked to neutral beam developments and

to the development of diagnostic components. In particular, in-situ diagnostics of the plasma facing surface have been studied.

Plasma Facing Component (PFC) developments, Vacuum Vessel/Blanket activities and Remote handling studies are

carried out inside the field “Vessel/In-Vessel”. The manufacturing of the ITER Primary First Wall (PFW) panel by HIP forming has been investigated. A dummy mock-up was produced to validate the manufacturing feasibility. In collaboration with BAE Systems, the Euratom-CEA Association has investigated a new welding process, able to improve welding productivity by several times compared to the ITER welding reference process. It is based on a hybrid laser/TIG process called Hybrid Laser Conduction Welding (HLCW). A ITER first wall mock-up (a combination of copper alloy as heat sink material, stainless steel as structural material and beryllium tiles as an armour material) have been successfully manufactured using induction brazing. This process limits the over-temperature exposure of the CuCrZr copper alloy. The Euratom-CEA Association performs a R&D program to demonstrate the feasibility of close inspection of the ITER Divertor cassettes and Vacuum Vessel first wall. The work performed includes design, manufacture and testing of an articulated multipurpose tool demonstrator called Articulated Inspection Arm (AIA), able to operate under temperature (120°C) and vacuum (10-6 Pa). In 2004, a single module prototype was manufactured and successfully tested in a specific device at Cadarache.

In the field “Magnets”, Euratom-CEA Association was involved to provide input information for establishing the final

dimension details of the ITER cryoplant. The Euratom-CEA Association is also involved with the design of different parts of the ITER magnet system: thermohydraulic properties of cable-in-conduit conductors with a central channel, design and fabrication of mock-ups for some critical parts of the ITER coils (He inlet), tests of ‘high performance’ Nb3Sn superconducting strands, joints development.

The Field “Tritium Breeding and Materials” includes for a large part reactor relevant activities. Within the frame of test

breeding module (TBM), activities mainly concerned the improvement and completion of the TBM engineering design. After a first design step in which the main structure, its functional features, its mounting sequence and manufacturing characteristics were defined, the second step, relied on the optimization of the design and manufacturing of the module as well as its integration to the supporting frame. A planning and list of test requirements for the qualification of the HCLL TBM was defined. A preliminary testing programme for the HCLL TBMs in ITER has been proposed on the basis of the foreseen ITER scenario and of the TBM testing strategy and mock-ups test objectives. Manufacturing of relevant mock-ups are under progress. Within the frame of the Helium Cooled Pebble Bed (HCPB) concept programmes, studies about the development of Li2TiO3 pebbles are on going. A new batch of 1 kilogram of pebbles with the size distribution in the range 0.6 to 0.8 mm was produced in 2004. The characteristics of pebbles are in agreement with the specifications for the Li2TiO3 pebbles. Two kilograms of pebbles were delivered for the HE-FUS 3 mock-up tests at ENEA and one sample of optimized 6Li enriched Li2TiO3 pebbles was delivered for the irradiation experiment at NRG. Euratom-CEA has a significant involvement in the development of structural materials for a fusion reactor, mainly focused in Europe on the EUROFER, a reduced activation martensitic steel. The irradiation behaviour of this alloy at high doses and for irradiation temperatures lower than 400°C is performed in irradiation experiments conducted in the BOR60 reactor of the Russian Research Institute of Atomic Reactors. As expected, all materials harden during irradiation, but RAFM steels and in particular EUROFER 97, present the lower level of hardening and the higher ductility compared to

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conventional 9Cr1Mo steels. ODS-Fe-14%Cr-Y2O3 ferritic alloy, having a fine grain structure, display also an interesting behaviour as RAFM steels. Euratom-CEA Association is also involving in the modelling irradiation effects programme by providing a database of Ab-initio defect energy calculations in the Fe-He system.

“Safety and Environment” studies realized by Euratom-CEA cover different parts of this topic such as code validation

experiment. The PACTITER code, an adaptation of the PACTOLE code developed for Pressurized Water Reactor, has been used for predicting the Activated Corrosion Products activities in the various Primary Heat Transfer Systems or Tokamak Water Cooling Systems (TWCS). A new tests campaign has been performed in 2004 in the new CORELE-2 loop to determine release rates of 316L under ITER TCWS operating conditions.

Activities performed in the field “System studies” are dedicated to the Power Plant Conceptual Studies (PPCS). In 2004,

activities were focused on the reactor model AB, based on a Helium-Cooled Lithium-Lead (HCLL) blanket. The model AB reactor is a suitable near term fusion power reactor able to supply 1.5 GWe to the grid with a gross efficiency of near 44%. Because of the high pumping power required by He-cooled systems, the net efficiency is reduced to about 35%. The HCLL blanket allows to achieve a TBR of 1.13.

Activities carried out in the Field “JET

technology” are devoted to the study of different processes which can be used for tritium removal from carbon materials, “Housekeeping” materials, vacuum oil and organic liquids. 2004 activities have also been devoted to the plasma facing components thermo-mechanical modelling, and to the JET diagnostics and divertor enhancement.

Three specific operational divisions of the CEA, located on four sites (see appendix 5), are involved in the Euratom-CEA fusion activities:

the Nuclear Energy Division (DEN) , for In-vessel component design (first wall, divertor, blanket, …), neutronics, structural materials and safety activities,

the Technology Research Division (DRT), for activities dedicated to materials (elaboration, breeding materials) and robotics,

the Physical Sciences Division (DSM), which includes the Controlled Fusion Research Department (DRFC) operating Tore Supra and responsible for plasma physics, cryoplant and magnet and plasma facing component activities.

The Euratom-CEA programme in Technology is also completed by specific R&D collaborations with industry in the fields of safety (Technicatome) and with the French National Centre for Scientific Research in the Plasma Facing Component activities. Progress in fusion technology is constant over the years and this report once again highlights a number of important steps that have been accomplished in this domain. Euratom-CEA, together with other European Institutions is on the foreground of technological advances which are of prime importance for the success of the ITER construction. On the longer term, progress in technology will improve the vision of an electricity producing reactor and will increase the credibility of fusion energy as a genuine energy for the future. The authors and the editors should be commended for their dedicated contribution in making this report available.

M. CHATELIER

TP TV TM TT TS TR TE TD TJ THUT

EFDA

TP : Physics TV : Vessel/In-Vessel TM : Magnets TT : Tritium breeding and Materials TS : Safety and Environment

TR : System studies TE : ITER Site Preparation TD : Design Support and Procurement TJ : JET Technology TH : Heating Systems Technology Project

EFDA : European Fusion Development Agreement UT : Underlying Technology

Figure 1 : breakdown of the work carried out by Field

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EUROPEAN FUSION DEVELOPMENT AGREEMENT TECHNOLOGY PROGRAMME

1 - Physics - Plasma Edge - Heating systems - Diagnostics

2- Vessel/In Vessel - Vessel-Blanket&Materials - Plasma Facing Components - Assembly and Maintenance

4 - Tritium Breeding and Materials - Breeding blankets - Materials development

8 - Design Support & Procurement

6 - System Studies - Power Plant

3 - Magnet structure

7 - ITER Site Preparation - EISS - Site & Plant Layout

9 - JET technology

10 - Heating Systems Technology Project

5 - Safety & Environment

Underlying Technology

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