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Lumsdaine, Arnold

Publications and source records attributed to Lumsdaine, Arnold.

18 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Design and analysis of actively-cooled, edge-transport diagnostic for long-pulsed operation in WEST

Next step fusion devices that will operate in steady-state will require complex plasma-facing components (PFCs) that can survive the harsh environment over long timescales not common in current devices. This will require robust plasma facing surfaces that are integrated with active cooling systems. In a collaboration between CEA and ORNL, a plasma-interacting diagnostic is being designed for the W Environment in Steady-state Tokamak (WEST) in Cadarache, France which requires plasma-facing protection like those needed for steady-state PFCs. This integrated diagnostic studies edge transport and impurity migration within WEST, and is planned to include imbedded temperature Langmuir probe sensors, as well as removeable sample slots for ex-situ surface analysis of plasma-material interactions. The entire assembly is expected to move into the plasma edge for periods up to 1000 s having an energy removeable capability of ∼6 kW and seeing a peak heat flux of more than 7 MW/m2. The assembly compliments WEST high fluence campaigns that plan for multiple 1000 s pulses. Within these specifications, the assembly will require a refractory metal plasma facing surface and integral cooling in order to function within the limited space allotted for such diagnostics. Because of the limited space and linear actuator needs, additive manufacturing of the high heat flux working end of the assembly is being considered which could allow for precision cooling-channels and lighter weight designs. Conceptual design along with simulation and analysis results will be presented for this complex diagnostic with novel PFCs.

Lumsdaine, Arnold↗
DOE OSTI2023

Material Plasma Exposure eXperiment High Heat Flux Microwave Absorber Design, Manufacture, and Articles Test

The Material Plasma Exposure eXperiment (MPEX) at Oak Ridge National Laboratory is in the final design phase. MPEX will be capable of exposing neutron-irradiated materials to plasmas for the study of plasma-material interaction. This facility will provide information about the complex effects of plasmas on materials and contribute to examining new materials that can withstand high heat fluxes and high ion fluences for future fusion devices. MPEX plasma is heated by 70-GHz or 105-GHz electron Bernstein wave/electron cyclotron heating (ECH), and the high-frequency microwaves are prone to scattering microwave power, which can have detrimental effects, especially on diagnostic components. A large portion of the injected ECH power is expected to be absorbed by plasma, but the remainder requires that microwave absorbers be placed immediately upstream and downstream of the ECH launcher to minimize stray microwaves leaving the ECH region. These microwaves can inadvertently heat components that cannot be shielded or otherwise protected. The microwave absorber design is based on an array of pyramid-shaped ceramic tiles brazed to a water-cooled explosion-bonded heat sink and a stainless steel plate to produce one tile module. Computational fluid dynamics and structural analyses were performed to optimize and validate the design. Multiple test coupons were produced to validate the process for brazing the two different tile materials to the Glidcop AL-15 baseplate. The articles were tested to evaluate the reliability and thermal performance through exposure to an electron beam with a heat flux of up to 1.5 MW/m2. Nondestructive testing was performed before and after testing to identify voids or separations that may have been introduced by the high heat flux. This paper discusses the details of high heat flux microwave absorber design, manufacturing details and associated challenges, and test results, demonstrating the effectiveness of the proposed design.

Hussain, Aftab↗
DOE OSTI2023

Plasma production and ion heating systems for the Material Plasma Exposure eXperiment

Plasma production and ion heating in the Material Plasma Exposure eXperiment (MPEX), whose design is nearing completion, is accomplished using continuous wave RF power with average power density up to 1.6 MW/m2 at the plasma interface. Plasma is produced using helicon waves coupled through a single helical antenna at 13.56 MHz with power supplied by three 100 kW fixed-frequency RF generators feeding a power combiner network followed by the matching network and launcher. The helicon source can utilize various gasses including hydrogen, deuterium, and helium, with a magnetic field strength in the source region up to 0.2 T, and maximum device |B| of 2.5 T. Power is coupled to ions via ion cyclotron heating at the fundamental resonance using a pair of phased helical antennas operating in the frequency range 4-9 MHz, that launch waves towards the resonance from the antenna region where ω > ωci. ICH power is supplied by a single 500 kW tunable RF transmitter through a 90° power splitter and matching/decoupling network. In the case of both the helicon and ICH systems the antennas are located external to the vacuum, with power transferred through novel water-cooled coaxial vacuum windows consisting of fused quartz outer cylinders and silicon nitride inner cylinders with forced convection water cooling between them. The antenna enclosures are pressurized with dry air to 3 bar absolute for voltage standoff.Several 3-D COMSOL models have been created to simulate the two systems. A model of the helicon region utilizing a cold plasma dielectric tensor with accurate magnetic field and realistic plasma density profiles has been used to calculate the plasma loading/complex antenna input impedance at the launcher feed for various ne and |B| values, for the purpose of estimating power handling. It also incorporates the geometry of all launcher structures relevant to this determination. A still more detailed model of the launcher together with a lossy dielectric plasma surrogate has been used to determine RF electric field values and power losses in the device components.Similar models have been produced to predict the performance and power handling of the ICH launcher. For this device the impedance matrix of the two-element antenna array is calculated using a warm plasma model, necessary to properly determine the wave propagation and absorption.

Goulding, Richard↗
DOE OSTI2023

Final Design and Analysis of the Superconducting Magnets for the Material Plasma Exposure Experiment

The Material Plasma Exposure eXperiment (MPEX), which has completed its final design, is a new linear plasma device to advance the understanding of plasma-material interactions through the generation and delivery of plasmas as they are expected in future fusion reactor divertors. MPEX will be a steady-state device to study high-fluence exposures of plasma-facing materials and components. The requirements for the magnetic field at the heating stages and the target make the application of superconducting coils necessary. The final designs for the superconducting magnets have been developed using three cryostat designs with warm bore diameters of 65 cm and 156 cm. The large bores are required to for other systems such as vacuum, water cooling, and RF power. There are 19 superconducting coils in MPEX that are contained in six cryostats. Although design, fabrication, and testing for the magnets as stand-alone units are straightforward, challenges will arise during the integration of the system. Various field profiles will be used during operation. The magnetic field where the electron cyclotron heating occurs needs to operate at both 1.25 and 2.50 T. Analyses that have been performed on the final design include designing the coils and determining operating currents to meet field requirements, forces between cryostats, the effects of coil and/or cryostat movement, and quench analysis. To ensure that the magnetic field requirements are met, a plan for monitoring the magnetic field at specified locations has been developed which includes the effect of coil and/or cryostat movement.

Burkhardt, Earle↗
DOE OSTI2023

Final Design of Vacuum Pumping Systems for the Material Plasma Exposure eXperiment

The Material Plasma Exposure eXperiment (MPEX) vacuum pumping system is responsible for creating prototypic conditions in the plasma material interaction chamber that mimic those in a fusion reactor divertor region. Additionally, the vacuum system needs to minimize the pressure in the plasma heating region to improve the coupling of the electron cyclotron heating and ion cyclotron heating to the plasma, minimizing waste heat exhausted to high heat flux components. Here, the final design of the system has been sized to comply with the vacuum pump operating environment and to reduce the number of unique pumps required while meeting performance requirements. Bounding cases with and without the plasma present have been developed in the pumping analysis, and an initial calculation has been performed based on the plasma pumping identified in Proto-MPEX operation though this result will remain unverified until MPEX operation.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Final Design of the Material Plasma Exposure eXperiment

The Material Plasma Exposure eXperiment (MPEX) has completed its design phase. MPEX will be a unique facility to investigate plasma material interactions (PMIs) under fusion prototypic divertor conditions in steady state. This includes plasma exposure conditions expected in a fusion reactor divertor. Materials to be investigated will include solids, liquids, and neutron pre-irradiated materials. Electron and ion heating will allow for a large operational domain ranging from erosion-dominated PMI conditions to deposition-dominated PMI conditions. An overview of the final design for all MPEX systems is given. Here, in particular, it is shown how mission-driven project requirements have led to detailed design choices with innovative solutions. Examples are the water-cooled helicon window, the electron cyclotron heating launcher, the target holder and manipulator, and the autonomous decouplers.

Fusion reactor↗
DOE OSTI2022

Material Plasma Exposure eXperiment (MPEX) High Heat Flux Bellows for Component Alignment in High Microwave Environment

The Material Plasma Exposure eXperiment (MPEX) device is a linear plasma device developed to perform plasma material interaction experiments under the conditions prototypic of a fusion reactor divertor. MPEX has multiple systems that must be precisely aligned to the plasma axis, including an electron cyclotron heating system that emits up to 400 kW of microwave power into the vacuum vessel. Five distinct systems require precise alignment on the MPEX device, thus requiring four bellows, all of which are adjacent to the plasma at a relatively high heat flux of approximately 47 kW/m2 and microwave power regions. The MPEX high heat flux bellows (HHFB) is designed to deliver 6 degrees of freedom positioning. The HHFB includes titanium–zirconium–molybdenum (TZM) inserts that are brazed into a Glidcop AL-15 body using a high-temperature braze alloy, thus blocking direct line of sight to an edge-welded bellows from the plasma and microwave screen to block microwaves from the bellows. Further, a custom ConFlat knife edge is machined into the Glidcop AL-15, so the vacuum flanges do not need a braze or weld joint on the vacuum interface. Fingerstock or copper mesh is used to restrict microwave power from entering the interstitial space between the water-cooled Glidcop AL-15 body and edge-welded bellows. Glidcop AL-15 was selected as the material of choice for the water-cooled body because it can maintain mechanical integrity at elevated temperatures, and it also allows for a high-temperature braze. TZM was selected for its machinability and compatibility with vacuum and plasma requirements. A test article is also being considered for a similarly shaped component, the MPEX limiter, that will demonstrate the integrity of the braze joint under high thermal load. Results from this testing will be extrapolated to deduce the lifetime and integrity of the HHFB design.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Erosion of tungsten marker layers in W7-X

In order to get first insight into net tungsten erosion in W7-X, tungsten (W) marker layers were exposed during the operational phase OP 1.2b at one position of the Test Divertor Unit (TDU), at 21 different positions of the inner heat shield, and at two scraper elements. The maximum tungsten erosion rate at the TDU strike line was 0.13 nm s -1 averaged over the whole campaign. The erosion was inhomogeneous on a microscopic scale, with higher erosion on ridges of the rough surface inclined towards the plasma and deposition of hydrocarbon layers in the recessed areas of the rough surface. The W erosion at the inner heat shield was below the detection limit of 3–6 × 10 12 W-atoms/cm 2 s, and all inner heat shield tiles were covered with a thin B/C/O layer with thickness in the range 2 × 10 17 –10 18 B + C atoms/cm 2 (about 20–100 nm B + C). W-erosion of the marker layers on the scraper elements was also below the detection limit.

Mayer, M↗
DOE OSTI2021

Steady-State Mechanical Analysis for Target Assembly in the Material Plasma Exposure eXperiment Facility

The Material Plasma Exposure eXperiment (MPEX) steady-state linear plasma facility is currently under design at Oak Ridge National Laboratory to expose target specimens to fusion divertor regimes. The neutron-irradiated target is actively cooled and remote handled in the MPEX facility for conducting plasma-material–interaction (PMI) experiments. Here, the steady-state stresses in the target and target assembly system are investigated using two-dimensional (2-D) and three-dimensional (3-D) models to provide expected stresses/strains under the heat loads to which various system components would be exposed during MPEX operation. The calculated temperatures from the 2-D axisymmetric mechanical model were found to be in excellent agreement with those from the full 3-D thermohydraulic model, providing a strong model validation. Numerical simulation results for the steady-state mechanical model indicate nonuniform distributions for the temperature, stress, and deformation within the critical components. For the initial design, the deformation results indicate possible gap openings between contacting surfaces below the plasma-facing materials. To reduce the possibility of interfacial gap opening, the target assembly was slightly changed and evaluated using the 2-D stress model. Numerical simulation results indicate that the interfacial gap openings can be minimized without drastically changing the entire target assembly. The stress-strain conditions for the target will be further used to assess the appropriate operation during MPEX experiments and gain insight into materials science phenomena during PMI.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Analysis of Design Alternatives of Actively Cooled RF Window for MPEX

The Materials Plasma Exposure eXperiment (MPEX) has been designed as a linear plasma divertor simulator in order to address plasma material interaction (PMI) science for next-generation fusion devices. It will have the capability to test neutron irradiated samples with plasma fluxes of greater than 10 24 m -2 s -1 . It is expected to operate steady state for up to 10 6 s to consider PMI affects through reactor end of life. The conceptual design of MPEX was completed in 2019, with preliminary design having begun in 2020. The plasma source for MPEX is a helicon antenna, where the energized helical antenna sits outside of the vacuum in order to minimize impurities in the plasma. It is expected to receive up to 200 kW of continuous power, and so the antenna and the window must be actively cooled. The water-cooled copper antenna has been operated at full power on the Proto-MPEX device (which is a test facility to demonstrate the plasma source and heating systems). The water-cooled window, however, is a novel component that must meet numerous competing requirements. It requires a low dielectric loss to allow the Radio Frequency (RF) power to create the plasma within the vacuum boundary. It must be structurally robust to handle the significant heat flux from the plasma and any heat from dielectric coupling. It must be compatible with the coolant (preferably water). It requires a vacuum seal that minimizes impurities into the plasma and does not compromise the structural integrity of the window. Two window designs have been tested. Results from these tests, where temperatures are measured and heat fluxes inferred from infrared camera data, have been correlated with thermal-structural simulations. When these simulations are extrapolated to the full power steady-state heat fluxes that are expected in MPEX, the designs do not appear to have the necessary structural robustness. This study explores design alternatives for the MPEX helicon antenna window, presents analysis results for several of the alternatives, and shows a viable solution that satisfies the requirements for MPEX operation.

Tipton Jr, Joseph↗
DOE OSTI2021

Superconducting Magnet Qualification Methodology for the Material Plasma Exposure Experiment

The Material Plasma Exposure eXperiment (MPEX), currently under design, is a new linear plasma device to advance the understanding of plasma-material interactions through the generation and delivery of plasmas as they are expected in future fusion reactor divertors. MPEX will be a steady-state device to study high-fluence exposures of plasma-facing materials and components. The requirements for the magnetic field at the target and the heating stages make the application of superconducting coils necessary. Conceptual designs for the superconducting magnets have been developed, and multiple cryostats with warm bore diameters of either 65 cm or 156 cm are envisioned to facilitate their integrated and timely assembly with other systems such as vacuum, water cooling, and RF power. Although design, fabrication, and testing for the magnets as stand-alone units are straightforward, challenges will arise during the integration of the system. Two different field profiles will be used during operation. The magnetic field where the electron cyclotron heating occurs needs to operate at both 1.25 and 2.5 T. It is critical that the magnets all share the same magnetic axis and alignment. The mutual inductance between cryostats will affect the quench behavior of the system. Also, cryostat-to-cryostat forces can be as large as 700 kN, and the magnitude and direction will change depending on which coils are energized. The design of the system must take those characteristics into account along with the quench scenarios. This paper describes the qualification approach that will be used to determine whether stand-alone tests can be used to ensure the success of the integrated system. Fiducials will be used to define the location of the magnetic axis for each cryostat to ensure proper alignment. Quench tests of a single magnet will be performed at a current above the normal operating current to account for additional stored energy from the mutual inductance to adjacent cryostats. Also, a 1018 steel plate will be mounted on either end of a cryostat to simulate the cryostat-to-cryostat forces. Requirements for the size and location of the steel plates are described.

Burkhardt, Earle↗
DOE OSTI2021

Quench Protection Study of Superconducting Magnets for the Materials Plasma Exposure Experiment

To advance the understanding of plasma material interactions, the Material Plasma Exposure eXperiment (MPEX) is a new linear plasma device that will generate and deliver plasma relevant to future fusion reactor divertors. The operation of MPEX is planned to be steady-state in order to facilitate high fluence exposures of plasma facing materials and components. The desire for steady-state operation along with the magnetic field requires the utilization of superconducting coils. The superconducting magnet system for MPEX has been developed. The baseline model has six superconducting magnet and one room-temperature magnet subsystems. In order to protect multiple superconducting magnet systems, quench analysis was carried out to determine the best protection approach for each magnet type. Because the mutual inductance accounts for approximately 35% of the stored energy in the entire system, this must be considered when determining the peak voltages and temperatures during a quench. Two approaches for passive quench protection are considered: (1) self-protecting magnets and (2) use of diodes to sub-divide the coils. For both approaches, active quench detection will be used to ensure all coils are de-energized in the event of a quench. Results of the quench analysis for several quench scenarios are presented.

Burkhardt, Earle↗
DOE OSTI2021

Cryogenic Considerations for Superconducting Magnet System Design for the Material Plasma Exposure eXperiment (MPEX)

The Material Plasma Exposure eXperiment (MPEX) has been proposed as a facility to address plasma material interaction knowledge gaps to qualify and develop materials and technologies that surround plasma environments for future fusion reactors. Utilizing different radio-frequency (rf) heating technologies, MPEX is a linear plasma device that will generate fusion reactor–like plasmas with energies and particle fluxes at the target materials with electron temperatures of 1 to 15 eV, electron densities of 10 20 to 10 21 m -3 , and ion fluxes greater than 10 24 m -2 s -1 . Starting with the MPEX requirements with respect to magnetic fields between 0.1 and 2.5 T and warm bores of either 0.65 m or 1.56 m, conceptual designs for a superconducting magnet system have been developed that utilize multiple NbTi windings distributed across seven cryostats to accommodate rf heating, water cooling, and vacuum systems needed for MPEX. While the cryogenic and magnet technologies relative to the field and space requirements are mature, the integration of these technologies across multiple cryostats presents several technical and logistical challenges. An analysis of the preferred refrigeration approach, modular recondensing liquid helium cryocoolers, was performed. Utilizing a design margin of a factor of two, this approach is feasible within the current design requirements for MPEX with some considerations related to its implementation within the thermal shields and the magnet subsystem geometries.

Duckworth, Robert↗
DOE OSTI2021

Composites and additive manufacturing for high-field coil supports for stellarators

The utilization of composites layered on an additive manufactured substrate, for the production of coil supports for modular coils in small or middle size experimental stellarators is assessed. The focus of the study is a monolithic coil support comprising the coils of a half-period of a stellarator, somewhat similar to the ones in UST_2 and ARIES-CS stellarators. However, the concept may be applicable to quasi-monolithic coil supports (coil forms of NCSX type) or individual coil casings (W7-X type).Coil supports for stellarators require high precision, stiffness and strength for large contorted parts. Traditionally, monolithic coil supports are produced by steel casting/forging and final machining. This production method and material gives accurate, stiff and strong coil supports, but the method may be expensive for monolithic supports due to the geometrical complexity and required accuracy of the structure. In relation to those matters, this work investigates whether a monolithic coil support comprising an additive manufactured resin substrate, which is externally (outward from the coils) surrounded with a thick layer of fibre-reinforced resin, may achieve enough strength and stiffness under middle/high magnetic fields. Finite element calculations are produced to obtain the direction of the principal stresses and their values in compression and tension at different areas of the monolithic support, which is relevant for anisotropic materials. The feasibility of directional application of (carbon) fibres on the winding surface of the stellarator outward from the coils is experimentally tested on a scaled-down additively manufactured prototype of a monolithic support. The strength and stiffness of the composite structure appears sufficient for common magnetic fields in experimental stellarators, and the 3D-composite design and manufacturing was technically feasible.

Queral, Vicente↗
DOE OSTI2021

PISCES-RF: a liquid-cooled high-power steady-state helicon plasma device

Radio-frequency (RF) driven helicon plasma sources can produce relatively high-density plasmas (n > 1019 m -3 ) at relatively moderate powers (<2 kW) in argon. However, to produce similar high-density plasmas for fusion relevant gases such as hydrogen (H), deuterium (D) and helium (He), much higher RF powers are needed. For very high RF powers, thermal issues of the RF-transparent dielectric window, used in the RF source design, limit the plasma operation timescales. To mitigate this constraint, we have designed, built and tested a novel helicon plasma source assembly with a fully liquid-cooled RF-transparent window which allows steady state operations at high power (up to 20 kW) and successfully produces high-density plasma with both argon and H. Deionized (DI) water, flowing between two concentric dielectric RF windows, is used as the coolant. We show that a full azimuthal blanket of DI water does not prevent high-density plasma production. From calorimetry on the DI water, we measure the net heat removed by the coolant at steady state conditions. Using infra-red imaging, we calculate the constant plasma heat deposition and measure the final steady state temperature distribution patterns on the inner surface of the ceramic layer. The heat deposition pattern follows the helical shape of the antenna. We also show the consistency between the heat absorbed by the DI water, as measured by calorimetry, and the total heat due to the combined effect of the plasma heating and the absorbed RF. These results are being used to answer critical engineering questions for the 200 kW RF device materials plasma exposure experiment being designed at the Oak Ridge National Laboratory as a next generation plasma material interaction device.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

CFD Simulation of Helium Flow Loop Test Section

A helium flow loop is being assembled at Oak Ridge National Laboratory to analyze heat transfer enhancement for systems such as blanket and divertor components. To efficiently identify optimum geometries for heat transfer enhancement in these applications, simulation work is performed to optimize test section designs that are built and tested in the helium flow loop that operates at 4 MPa and a mass flow rate of 100 g/s. Different ribbed geometries that examine rib shape, rib height, rib orientation, rib spacing, and three dimensional orientation are modeled and simulated in STAR-CCM+ to compare their ability to remove heat and mitigate pressure drop. Following the simulations, models are selected and manufactured for the helium flow loop tests. Simulations initially focus on a hydrodynamic study to determine the appropriate mesh and physics models and then add a heat flux to analyze the heat transfer abilities of the models. The simulations are run in steady state and use a Reynolds-averaged Navier-Stokes k-ε turbulence model. The helium is modeled as an ideal gas. The simulation explores models of geometries that enhance the heat transfer and decrease pressure drop with an overall goal of increasing fluid collision with the wall. Enhanced geometries are simulated to select appropriate designs for manufacturing, and preliminary experimental results are used to validate the simulations. Furthermore, the factors that are being analyzed in the comparison between the experimental and the simulated results include matching thermocouple temperatures, pressure drop, roughness, and fluid velocity.

42 ENGINEERING↗