Test Blanket Module:

RAFMS Steels & Fabrication

Technologies

Institute for Plasma Research

Bhat, Gandhinagar

WS&FT-08, 21st July 2008, IPR

 INDIAN FUSION ROAD MAP
Power Plant 2050
Fusion Power Reactor

DEMO 2035
- Qualification of Technologies
- Qualification of reactor
components & Process

SST-2 2020
Indigenous Fusion Experiment

ITER Participation 2005

scientific and technological
feasibility of fusion energy

SST-1 2004
Steady State Physics and TBM Prototype
related technologies Program Programs
1986
ADITYA Tokamak
 DEMO Fusion Reactor Core

Breeding
Breeding
Blanket
Blanket
400-550°C Blanket
400-550°C

Vertical
Vertical
Manifold
Manifold
~320°C
~320°C Vessel
Neutron
Neutron
Shield
Shield
~320°C
~320°C
Divertor
Vacuum
Vacuum
Vessel
Vessel
~100°C
~100°C Magnet

DEMO = Demonstration Fusion Reactor Plant 3

-FZK
BLANKET
Functions

Tritium Breeding

High grade heat extraction

Radiation Shielding

4
 TBM Program in ITER
The ITER Basic Device has Shielding Blanket, but no Breeding Blanket

ITER mission : “ITER should test tritium breeding module concepts

that would lead in a future reactor to tritium self-sufficiency, the
extraction of high grade heat and electricity production.”

Breeding Blankets will be tested in ITER, by inserting Test Blanket

Modules (TBM) in specially dedicated ports

All the ITER Parties have their own TBM program and developing
indigenous Materials & Technologies.

CHINA, EUROPE, INDIA, JAPAN, KOREA, RUSSIA & US

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Frame

TBM

1.66 m (h) x 0.48 m (w) x 0.54 m (t)

Parameters ITER DEMO

Surface Heat 0.27 0.5
Flux (MW/m2)
Neutron wall 0.57 2.5
Loading
(MW/m2)
Pulse length Up to 3000 ~
(sec) continuous
Duty cycle 0.25 -

Avg. Neutron 0.1 7.5

Fluence (for initial 6
(MWa/m2) 10 years)
 Indian TBM Concepts

Lead-Lithium cooled Ceramic Breeder (LLCB)

 Tritium Breeder: Lithium-Titanate pebbles
 Breeder Coolant: Lead-Lithium eutectic alloy  (multiplier and breeder)
 Structural Material : Reduce Activation FMS

Solid Type: Helium Cooled Ceramic Breeder (HCCB)

 Tritium Breeder: Lithium-Titanate / Lithium Silicate pebbles
 Multiplier : Beryllium Pebbles
 Structural Material : Reduce Activation FMS
 Coolant : helium gas

7
 Lead-Lithium cooled Ceramic Breeder (LLCB) TBM

U-shaped First wall

Box structure Top Plate

Support

He Purge Outlet He Purge Inlet

Shear Keys
Outer Back Plate

Poloidal 1660 He Inlet

He Outlet
Toroidal 480
Radial 536 Pb-Li Inlet

Pb-Li Outlet
Bottom Plate
 LLCB TBM Parameters
LLCB

Top Plate

Outer Back Plate

Inner Back Plate

Ceramic
Breeder
zones

He Inlet/Outlet
concentric pipe
First Wall

Pb-Li Inlet pipe

Pb-Li Outlet pipe

Bottom Plate

Pb-Li Inlet Manifold

1.66 m (h) x 0.484 m (w) x 0.54 m (t)

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Helium as Purge gas for Tritium extraction
 TBM Materials
Structural material : Reduced Activation Ferritic Martensitic Steel
(RAFMS) and ODS

Tritium Breeder :
Solid : Li4SiO4, Li2TiO3
Liquid : Pb-17Li
Enriched Lithium : Li-6 (30 – 90 %)

Neutron multiplier : Be, Be12Ti, Pb

Composite Material : SiCf/SiC (FCI)

Coatings : Be, Alumina, Erbium oxide coatings

Neutron Shielding and External Piping : SS 316 LN-IG 10

 Key Material Issues in Fusion Devices

The 14 MeV neutrons produce transmutation nuclear reactions and atomic

displacement cascades inside the materials

Damage and transmutation imply degradation of physical and mechanical

properties of materials ( Swelling, Hardening, LD, LCS, LFT..)

DEMO: Radiation damage @ First Wall, End of life: 100 - 150 dpa (5 yr)
Transmutation to Helium: 1200 -1800 appm He

The existing sources of 14 MeV neutrons have a small intensity and do not allow
us to get important damage accumulation in a reasonable time.

It is necessary to simulate irradiation by 14 MeV neutrons (@ 550 C), by using

either fission neutrons, or high energy protons.

Presently, Materials are irradiated with fission neutrons and with high-
energy protons. Results are interpolated for fusion irradiation conditions.
 Structural Steels for TBM

RAFM Steel : 9Cr W Ta V Si, C

 Composition tailored to reduce activation and waste
 Operational Temperature window: 300-550°C
To be used as structural material for the TBM and in DEMO blankets

Oxide dispersion strengthened (ODS) Steels

(Potential Candidate to replace RAFMS)
 Operational Temperature window: 350-650°C
 Reduced Activation Ferritic Martensitic Steels (RAFMS)
Elements Wt. %
Process : Vacuum Induction Melting (VIM)
Cr 8.80 – 9.20
C 0.10 – 0.12 Typical RT 300 oC 500 oC
Mn 0.4 0 – 0.60
UTS (Mpa) 640 – 680 520 – 560 400 – 440
V 0.18 – 0.24
YS (E 0.2%)(Mpa) 540 – 580 465 – 485 385 – 40
W 1.0 – 1.20
Ta 0.07 – 0.10
DBTT : < -70 oC
N 0.02 – 0.04
O < 0.01 Plates of dimensions: (in mm)
P < 0.002 (i) 1700 L x 1500 W x 12-15 T
S < 0.002
(ii) 1700 L x 1500 W x 25-30 T
Rectangular tubes: (18mm x 18 mm)
B < 0.001
Powder &
Ti < 0.005
Wire form (for welding )
Nb < 0.001
Mo < 0.002
Ni < 0.005 Quantity Required:
Cu < 0.002 Each TBM (Typically) : ~ 5 Ton
Al < 0.005
To develop 8 TBMs in 15 years : ~ 40 - 50 Ton
Si < 0.05
IGCAR & MIDHANI jointly developing 13
Co < 0.005
 RAFMS Development : Critical Issues

Characterization and understanding of degradation due to neutron

irradiation ( ~ 550 C)

 3 -15 dpa (engineering database for TBM design, fabrication and TBM licensing)

Major Issues:
– Development of Reliable joints manufacturing process (HIP, EBW, LW etc..)
– Compatibility with Breeder Materials (Li-ceramics, flowing Pb-Li in magnetic filed)
– Anti-Corrosion / Anti-Permeation Barriers development
– Creep-Fatigue Interaction due to high temperature cyclic operation (data validation)
– High Temperature Design Criteria as per the ITER SDC (RCCMR & ASME)

LONG TERM R&D for the Development of fully qualified LAFMS material
 Modeling & Simulation
 Chemical Composition
 Characterization Mock-up fabrication
 Optimization of joining techniques
 Neutron irradiation
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 Industrial Production
 Long Term Needs
ODS alloys
Disadvantages with FMS
 DBTT decrease after irradiation at Tirr < 400°C;
 The welds need heat treatments
 Upper operating temperature limited by creep strength: Tmax  550°C
Possible solution: Tmax in range 550-650 °C by powder metallurgy Route (ODS)

ODS alloys Advantages Disadvantages

12-16% Cr ODS Higher temperature Anisotropic mechanical
ferritic steel capability properties
Better oxidation resistance Lower fracture toughness
9% Cr ODS ferritic/ Nearly isotropic properties Limited to temperature below
martensitic steel after heat treatment ~700 C
Better fracture toughness Marginal oxidation resistance at
Scalable fabrication high temperatures

 8-9.5 Cr , 1 % W and 0.3 %Y2O3 (50 nm size) without Titanium

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 Manufacturing Technologies
adopted for TBM

 HIPPING / INVESTMENT CASTING

 EB Welding
Testing Methods

 Hybrid (MIG/LASER)  Ultrasonic testing

 X-ray / γ-ray testing

 TIG Welding
 Dye Penetrant testing
 LASER Welding
 Helium leak tightness
 Component-1 : U-Shaped First Wall Box Structure
He Channel
(Top plate cooling)

He Channel
First Wall

HIPPING
Channel 20 x 20
mm
Or
No. of 64 Nos. Investment
Channel
He Channel
Casting
Corner 2.5 mm
Radius
Inside
Channel

Overall Dimension: 1.66 m (h) x 0.48 m (w) x 0.54 m (t)

 Typical Dimensions
(Reference EU Trials)
First Wall thickness : ~ 25 – 30 mm
HIPPING
Cooling channels : 15-18 x 15-18 mm2 (5 - 6 mm rib)
1000 oC, 130 MPa
Top & Bottom covers : 30 – 32 mm
Stiffening plates / flow divider wall thickness : 5 – 8 mm
Options
200

Built-in Cooling TBM FW

Channels

300

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 TBM FW mockup fabrication (EU - References)

200mm X 200mm X 100mm (height)

F82H as recieved 1040 ºC x 2hr x 150MPa

Grain Size # G ： 5 Grain Size #G ： 2
Grain Size ： 60m Grain Size ： 170m 19
Japanese Trials with RAFMS (F82H)

200

Built-in Cooling Channels

300

Horizontal Channels
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Component-2 Top Plate Assembly of LLCB TBM
Top Plate 1

Top Plate 2

Top Plate 3

Rib

BY HIPPING Or Investment Casting

 Dimensions of Top Plate-3 with Rib
(He Inlet/Outlet)

ISO View

Plate Thickness 4 mm
Rib Thickness 6 mm
Rib Width 4 mm
All Dimensions are in mm
Unspecified Corner Radius 2 mm
 Component-3 : Manifold
Arrangement with Inner Back Plate

Inner Back Plate

Breeder
First Wall
He Inlet fo
Back Plate

He Channel

Inner Back Plate

He Outlet f
Back Plate
Dimension of Inner Back Plate

Detail View
B

Channel 20 x 20
Dimension

Total No. 32
of
Channel

Unspecified Corner
Radius = 10 mm

Section View All Dimension Are in mm

A:A
 Manifold
Arrangement with Outer Back Plate

Outer Back Plate

First Inner Back
Wall Plate

He Outlet for He Channel

Back Plate
Outer Back
Plate

He Inlet for
Back Plate
Dimension of Outer Back Plate
HIPPING Joint Properties

EU Ref.

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 Investment casting
Investment casting is a potentially attractive alternative to HIP
for first-wall, grid plate and manifold fabrication

– Reduces the need for extensive joining which should improve reliability
(joints are typically the origin of structural failures)

– Reduces the amount of NDE needed (few joints).

– Potentially less expensive than other fabrication methods.

– Complex castings of 9-10 Cr steels have been produced with

mechanical properties similar to those of wrought products
(Ref: Valves & Steam Turbine applications)
 EB-Welding
Sound structural welds: Free of cracks, low pores
For High Depth Welding:
High voltage: 150 kV,
Welding current: 72 mA,
Travel speed: 0.3 m/min

40 mm and weld width 2 mm.

Macrography of Eurofer / 316LN

EBW (1.5 mm thick)

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 Major Tasks in EBW development

Development of welding procedure for thick RAFMS plates

Optimization of Welding process (current density, speed, environ.)

Characterization of weld joints (ITER-SDC  RCC-MR and ASME

codes)
– Radiography Test
– Effect of Post-Weld Heat Treatment on Hardness (needs
optimization)
– Effect of neutron Irradiation on weld joints (Microstructures,
Mechanical Properties (TS, DBTT, YS, FT)

Optimization of EBW process in actual TBM mock-ups (In real joint

configurations)
YAG LASER
LASER Welding (Reference EU R&D)

- Laser power: 4 kW
- Travel speed: 0.35 m/min Plate – Plate welding
- Focal length: 150 mm 5 - 8 mm to 12 – 15 mm
- Twin spot with d = 2.1 mm

Penetration of the melt run ranges typically from 4 to 8 mm

(WS = 130 cm/min).
Metallurgical analysis: hot cracks (max. 1.2 mm) and gas
pores (max.  0.7 mm).
RAFMS / EUROFER is sensitive to hot cracking.

Coolant Panels

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 LASER Welding on TBM Mock-up Trials

Join realized in 2 passes (Top

& Bottom)
Mode I: Successive and
opposite direction of the passes;
Mode II : Simultaneous and
same direction of the passes
Assembly mode I & II Clamping Conditions
(Reference EU R&D)

Dissimilar Joints (RAFMS/SS 316 LN)

SP- Fusion Butt welding
(YAG LASER) > 2 KW

Pipes Dia: 75 – 85 mm,

thick = 3 - 6 mm
- Metallographic
- Destructive / non-
destructive tests
Sr. Major Milestones (1/2) Completion
No. by:
1 Materials composition definition 12/2008

2 TBM Quality management system establishment (e.g., QA) 06/2009

3 Out-Of-Pile characterization of DEMO-relevant structural material 12/2009

and TBM fabrication process validation (at laboratory level)

4 TBM system conceptual design 12/2009

5 TBM Preliminary Safety Report (for each concept and dummy 12/2009
plug)

6 Small/medium size TBM mock-ups fabrication addressing critical 12/2010

components (industrial manufacture or, at least, industrially
compatible manufacture)

7 Small/medium size TBM mock-ups testing results 12/2011

8 Completion of data base for structural material and joints for use 6/2012
in design codes and codes & standards

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 Major Milestones (2/2)

9 Detailed design of the first TBM system to be installed in ITER day 06/2012
one (1st Plasma)

10 Completion of data base for structural material and joints under 06/2014
irradiation (at least, 3 dpa)

11 End of fabrication of large size TBM mock-up and associated 06/2014

system

12 End of testing and qualification of large size TBM mock-up and 12/2015
associated system in appropriate facilities

13 Delivery of TBM systems to ITER 12/2016

14 End of 1st TBM System acceptance tests (e.g., leakage tests, 12/2017
pressure tests, compatibility check with ITER interfaces) and
Commissioning
15 TBM Safety Report to be provided with QA records during 12/2017
construction and reception tests
 Summary
Materials Requirement and related Manufacturing technologies for
TBM development has been projected

The fabrication technologies development for TBM need to be

initiated through mock-ups and prototype fabrication and testing

The qualification according to codes and standards needs to be

finalized and harmonized as per the ITER requirements

The budget for the TBM Program is available.

We invite R&D centers to initiate the developmental activities for a

committed delivery to meet the ITER time schedule
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Thank you

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 Irradiation Modes

• Fusion neutrons, fission neutrons, high energy protons:

• Strong differences in the production rates of impurities

Defect Fusion neutrons Fission High energy

poduction (3-4 GW reactor, neutrons protons
(in steels) first wall) (BOR 60 reactor) (590 MeV)
Damage rate
20-30 ~ 20 ~ 10
[dpa/year]
Helium
10-15 ≤1 ~ 130
[appm/dpa]
Hydrogen
40-50 ≤ 10 ~ 800
[appm/dpa]
 Effect of 300°C Irradiation on Eurofer97
Base and EB Weld Metal Tensile Ductility
J.W. Rensman / NRG Irradiation Testing: Report on 300°C and 60°C Irradiated RAFM Steels (2005)

25 mm Plate Electron Beam Welded 25 mm Plate

 Effect of 300°C Irradiation on Eurofer97
Base and EB Weld Metal Impact Properties
J.W. Rensman / NRG Irradiation Testing: Report on 300°C and 60°C Irradiated RAFM Steels (2005)

25 mm Plate Electron Beam Welded 25 mm Plate

 Effect of Post-Weld Heat Treatment on Hardness of
Eurofer 97 EB Welds

J.W. Rensman, E. Rigal, R. Meyder, A. Li Puma / ICFRM-12 (2005)

• Research needs:
– No systematic study of all
variables in the literature.
There is a need to
understand the controlling
variables to optimize weld
and PWHT for irradiation
response.
– Irradiation testing of very fine
grained HAZ.
– Irradiation testing of base
and weld metal with multiple
PWHTs.