New, Ultra-Low Cost Fabrication Methods. By L. M. Waganer The Boeing Company With support from D. A. Deuser, K. T. Slattery, and G. W. Wille of The Boeing Company F. Arcella and B. Cleveland of AeroMet Corporation US/Japan Workshop on Fusion Power Plant Studies And Advanced Technologies
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New, Ultra-Low Cost Fabrication Methods
L. M. Waganer
The Boeing Company
With support from
D. A. Deuser, K. T. Slattery, and G. W. Wille of The Boeing Company
F. Arcella and B. Cleveland of AeroMet Corporation
US/Japan Workshop on Fusion Power Plant Studies
And Advanced Technologies
16 -17 March 2000
Laser or Plasma Arc Forming
This elevation view is the basis for the engineering cost estimate of the TF coil system.
There are four distinct
Conventional TF coil fabrication is too expensive
Thick Aluminum Return Conductor
Fabrication of all parts would be labor intensive!
Conventionally-Machined Ti-6Al-4V Part
Examples of Fabricated Parts
AeroMet Corporation has produced a variety of titanium parts. Some are in as-built condition and others are machined to final shape.
thick shell cross-section
Material Cost =$0.29 M
Labor Cost =$2.31 M
Contingency =$0.50 M
Total Cost=$3.39 M
This unit cost is representative of conventional fabrication
Schematic of Spray Casting Process
Molten Metal Furnace (Courtesy of SECO/WARWICK, Inc.)
3. TF Return Shell Cost Development
$270 M for
ComponentFinished MassTotal CostUnit Cost
Copper Centerpost0.85 Mkg$6.88 M$8.09
TF Vacuum Vessel0.04 Mkg$3.39 M$85.14
Al Spray Cast Shell 2.69 Mkg$13.05 M$4.85
TF Coil System3.58 Mkg$23.32 M$6.51
Use of these low-cost, highly-automated fabrication techniques for the centerpost and TF return shell has the promise of reducing the capital cost by $200M -$300M and lowering the cost of fusion-generated electricity by approximately 10% for this application.