Abstract
The thermal performance of a carbon fibre composite-copper monoblock, a sub-component of a fusion reactor divertor, was investigated by finite element analysis. High-accuracy simulations were created using an emerging technique, image-based finite element modelling, which converts X-ray tomography data into micro-structurally faithful models, capturing details such as manufacturing defects. For validation, a case study was performed where the thermal analysis by laser flash of a carbon fibre composite-copper disc was simulated such that computational and experimental results could be compared directly. Results showed that a high resolution image-based simulation (102 million elements of 32μm width) provided increased accuracy over a low resolution image-based simulation (0.6 million elements of 194μm width) and idealised computer aided design simulations. Using this technique to analyse a monoblock mock-up, it was possible to detect and quantify the effects of debonding regions at the carbon fibre composite-copper interface likely to impact both component performance and expected lifetime. These features would not have been accounted for in idealised computer aided design simulations.
Highlights
ITER, currently under construction, will be the world’s largest nuclear fusion reactor
In the first case study, laser flash analysis was carried out for a carbon fibre composites (CFC)–Cu disc where the interface had been joined by a novel brazing process using a Gemco foil pre-coated with chromium
It was shown that the thermal conductivity of the CFC–Cu disc decreased by 35% over a temperature range of 100 ◦C to 700 ◦C
Summary
ITER, currently under construction, will be the world’s largest nuclear fusion reactor. The plasma in which the reactions happen will subject the plasma facing components (PFCs) to around 10 MW m−2 of thermal flux during steady-state operation. This value could be surpassed if plasma disruptions which release large amounts of energy over short time periods are not mitigated [1]. Selection of materials for the PFCs is largely governed by their ability to withstand such a hostile environment whilst absorbing neutronic heating, minimising plasma impurities and protecting components shielded by the PFCs. Ll.M. Evans et al / Fusion Engineering and Design 100 (2015) 100–111
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