Christian Zeile Supervisor: Heiko Neuberger Contributors: HCPB TBM-Team, Bernhard Dolensky

1. ITER GOT PPE Training Session / Cadarache WP4 – Design, manufacturing and integration of ITER relevant structural components Christian Zeile Supervisor: Heiko Neuberger Contributors: HCPB TBM-Team, Bernhard Dolensky Institute for Neutron Physics and Reactor Technology (INR)

2. Outline • Introductory and Training Courses • Introductory practical work • Design and Analysis of Structural Components • Studied component: Attachment-System • Location of Attachment-System • Boundary conditions • Existing concepts • Carried-out analysis • New concepts • Connection between Attachment-System and Shield • Outlook / Future Work Christian Zeile

3. Introductory and Training Courses Engineering Tools: • CATIA V5 Training: Basic and advanced (2 weeks) • Ansys Workbench and Classic • PDM System: Smarteam Project relevant introduction: • Training session at JET (June 09) • Summer School on Fusion Technology in Karlsruhe (September 09) Project relevant meetings: • Design Coordination Meeting (July 09) • Monitoring Meeting CoA and F4E (October 09) Christian Zeile

4. Introductory practical work Involvement in the layout of a heater integration in a structural component: Goal: Simulation of volumetric heating (neutron radiation) Boundary conditions: Neutronic heat generation analysis and resulting temperature distribution Christian Zeile

5. Introductory practical work Approach: • Development of different concepts • Preliminary calculation of required heat generation rates and appropriate locations for the heaters Heaters attached to box structure surfaces Heaters inside pebble beds Constant power level Staged power level No realistic temperature distribution inside the breeder unit Relevant thermal expansion of box structure Fewer heaters required Realistic temperature distribution inside the breeder unit Christian Zeile

6. Introductory practical work Approach: • Development of different concepts • Preliminary calculation of required heat generation rates and appropriate locations for the heaters • Study of different electrical heater concepts • Contact with electrical heater manufacturers in order to check the feasibility Bach RC Watlow Plate heaters Cartridge heaters Christian Zeile

7. Design and Analysis of Structural Components Studied component: Attachment-System of plasma facing structural components Using the example of the HCPB Test Blanket Module (TBM): • 4 main tasks: • - Shield sensitive components of radiation • Breed tritium (inside Breeding Units) • Transform kinetic energy of neutrons into thermal energy • Transmit thermal energy to cooling circuit Christian Zeile

8. Backplate TBM Port Plug First Wall Interface 1: Location for Attachment-System Shield Design and Analysis of Structural Components Location of the TBM inside a fusion reactor Christian Zeile

9. Design and Analysis of Structural Components Boundary conditions (1/2): EM loads poloidal Normal operation: Maxwell forces Plasma disruption: Maxwell forces + Lorentz forces 50 kN toroidal 142 kNm 42 kNm 27 kN radial 360 kNm 370 kN Christian Zeile

10. Design and Analysis of Structural Components Boundary conditions (2/2): Thermal loads The temperature gradient between First Wall and Backplate leads to a deformation of the Backplate Temperature distribution dependent on design Christian Zeile

11. Design and Analysis of Structural Components Simplified model of the TBM-Box (1/2) • Required for fast preliminary analysis • Similar stiffness behaviour as complex model • Simplification of the geometry: • Deletion of edge fillets • Merging of cooling channels • Simplification of pockets Christian Zeile

12. Design and Analysis of Structural Components Simplified model of the TBM-Box (2/2) Comparison of simplified and complex model • Different load cases are considered • Maximum allowed deviation : 10% Christian Zeile

13. Design and Analysis of Structural Components Existing concepts of the Attachment-System (1/3): CEA-Concept • Upper and lower key provide rigid contact to withstand the high radial torque • Central flexible element resists the thermal expansion and the structural loads except radial torque Christian Zeile

14. Design and Analysis of Structural Components Existing concepts of the Attachment-System (2/3): Concept with shear keys and flexible cartridges Concept with keys and bolts Christian Zeile

15. Design and Analysis of Structural Components Existing concepts of the Attachment-System (3/3): KIT-Concept • All structural loads distributed on the four Attachment blocks • High stiffness in the direction of the high torque • Low stiffness in the direction of the thermal expansion Lamellas Christian Zeile

16. Radial force Maximum equivalent stress under radial force 97 MPa Maximum equivalent stress with additional thermal expansion Radial force + thermal expansion 268 MPa (rough estimation of temperature distribution in TBM-Box) Strong effect of thermal expansion on total stresses Design and Analysis of Structural Components Analysis of KIT Attachment-System considering thermal expansion and additional stiffness due to the TBM-Box Former analysis without considering thermal expansion and preliminary simplified box model Maximum equivalent stress under radial force Analysis including thermal expansion and new simplified box model 52 MPa Christian Zeile

17. First analysis Roll (rotatory motion) discarded Cage (translational motion) Design and Analysis of Structural Components Development of new concepts • + high stiffness • + no flexibility necessary • - Difficult manufacturing • Difficult assembly • space requirement Christian Zeile

18. TBM (Attachment-System attached by welding) Shield Design and Analysis of Structural Components HCPB-TBM Design Proposal: Different connection concepts between Attachment-System and Shield Requirements: • Feasible connection of two different materials (Eurofer-Stainless Steel) • Feasible assembly in limited space • Transfer of high dynamic forces Possible approaches: • Screw coupling • Positive locking • Welding of different materials • Combination of these connection types Christian Zeile

19. Design and Analysis of Structural Components Concept 1: Screw Coupling • + lower tolerances required before assembly • + easy assembly • only friction contact Christian Zeile

20. Contact loss Design and Analysis of Structural Components Concept 2: Screw Coupling and Welding of identical materials • + lower tolerances required before assembly • + easy assembly • + large area of contact • high space requirements • only friction contact Christian Zeile

21. Design and Analysis of Structural Components Concept 3: Positive Locking • + forces transferred by positive locking • + easy assembly • high precision of contact surfaces required Christian Zeile

22. Design and Analysis of Structural Components Concept 4: Welding of different materials • + lower tolerances required before assembly • Accessibility for the welding tool • Welding process has to be qualified according to codes and standards • Heat: • Effects of distortion • Diagnostic Christian Zeile

23. Outlook / Future Work • Check of feasibility with manufacturing team 2010 • Consolidated design and analysis • Design of relevant mock-up • Evaluation of Process Parameters 2011 • Organisation of mock-up fabrication • Destructive testing Training courses: • Project relevant design codes (ASME, RCC) 2010 • Project Management • Quality Assurance… Christian Zeile

24. Thank you for your attention Christian Zeile