![Page 1: Synthesis, characterization and FE-modeling of a W/CuCrZr FGM joint EUROMAT 2011 – Montpellier 12-15-09.2011 a IPP, Max-Planck-Institut für Plasmaphysik,](https://reader036.vdocuments.mx/reader036/viewer/2022062500/5697bf7c1a28abf838c83d56/html5/thumbnails/1.jpg)
Synthesis, characterization and FE-modeling of a W/CuCrZr FGM joint
EUROMAT 2011 – Montpellier 12-15-09.2011
a IPP, Max-Planck-Institut für Plasmaphysik, Garching bei Munich, Germanyb IfWW, Institut für Werkstoffwissenschaft, Technische Universität Dresden, Dresden, Germanyc ESRF European Synchrotron Radiation Facility, Grenoble, Franced IFAM, Fraunhofer-Institut für Fertigungstechnik und Angewandte Materialforschung, Dresden, Germany
A.Zivelonghia, S. Nawkab, A. Brendela, J.Riescha , M.di Michielc, M.Scheelc, T. Schubertd, J.-H. Youa and B. Kieback b,d
![Page 2: Synthesis, characterization and FE-modeling of a W/CuCrZr FGM joint EUROMAT 2011 – Montpellier 12-15-09.2011 a IPP, Max-Planck-Institut für Plasmaphysik,](https://reader036.vdocuments.mx/reader036/viewer/2022062500/5697bf7c1a28abf838c83d56/html5/thumbnails/2.jpg)
Outline
Conclusions & Outlook
Introduction Synthesis of a W-CuCrZr multilayer FGM
1
Characterization
Single layers manufactoring
Assembling the multilayer (ML)
Experimental measurements
FE-Modelling (meso and macroscale)
Optimization
EUROMAT 2011
![Page 3: Synthesis, characterization and FE-modeling of a W/CuCrZr FGM joint EUROMAT 2011 – Montpellier 12-15-09.2011 a IPP, Max-Planck-Institut für Plasmaphysik,](https://reader036.vdocuments.mx/reader036/viewer/2022062500/5697bf7c1a28abf838c83d56/html5/thumbnails/3.jpg)
Nuclear Fusion Reactors High Heat Fluxes on first wall to be removed
Materials for Extreme Thermal Environments
≥ 10 MW/m² ITER*, DEMO**
*G.Federici, Journal of Nuclear Materials (2009) **H.Bolt et al., Journal of Nuclear Materials (2004)
Interface Stress
FGM Joint
H2O
W: good plasma compatibility, highest Tm, high strength at high T
Cu: high conductivity, limited oper. T (< 300°C)
CuCrZr: improved strength (RT-550°C) higher operation T (up to 480°C)
higher power generat. efficiency
Plasma FacingComponent
2 cmEUROMAT 2011
![Page 4: Synthesis, characterization and FE-modeling of a W/CuCrZr FGM joint EUROMAT 2011 – Montpellier 12-15-09.2011 a IPP, Max-Planck-Institut für Plasmaphysik,](https://reader036.vdocuments.mx/reader036/viewer/2022062500/5697bf7c1a28abf838c83d56/html5/thumbnails/4.jpg)
EUROMAT 2011
W-Cu: High Mismatch Stress
σmax (Interface) ~ f(ΔαW-CuCrZr , ΔE, ΔT...)
CoolingOperation
550 MPa (tensile in W)
*J.H.You, H.Bolt, Journal of Nuclear Materials 299 (2001) 1-8
Sx
[MPa]-800 MPa
(compressive in W)
factor 4!10 MW/m²
![Page 5: Synthesis, characterization and FE-modeling of a W/CuCrZr FGM joint EUROMAT 2011 – Montpellier 12-15-09.2011 a IPP, Max-Planck-Institut für Plasmaphysik,](https://reader036.vdocuments.mx/reader036/viewer/2022062500/5697bf7c1a28abf838c83d56/html5/thumbnails/5.jpg)
5. Component size
1. Graded transition (layered or continuous)
Satisfying Demanding Requirements
3. Minimum porosity + good homogeneity
Requirements
4. High conductivity percolating CuCrZr
2. Higher strength (W/Cu* W/CuCrZr)
Sintering of Layered W-skeleton(100% open porosity)
+Infiltration
CuCr0,8Zr0,08 (wt%) +
Hardening
INFILTRATIONItho (1996), Ge (2005)R. Jedamzik (2000)D. Jankovic Ilic
Plasma SprayedPintsuk (2004), Ge (2005)
SPSiGe (2005)
W/Cu
![Page 6: Synthesis, characterization and FE-modeling of a W/CuCrZr FGM joint EUROMAT 2011 – Montpellier 12-15-09.2011 a IPP, Max-Planck-Institut für Plasmaphysik,](https://reader036.vdocuments.mx/reader036/viewer/2022062500/5697bf7c1a28abf838c83d56/html5/thumbnails/6.jpg)
FE-Modelling FGM Joint under realistic conditions
(residual and thermal stress)
Development Strategy
Joint optimization (ongoing)
Thermoelostoplastic Mat. Properties(including failure limits)
Characterization single layers [ W30%vol - W50%vol - W70%vol ]
![Page 7: Synthesis, characterization and FE-modeling of a W/CuCrZr FGM joint EUROMAT 2011 – Montpellier 12-15-09.2011 a IPP, Max-Planck-Institut für Plasmaphysik,](https://reader036.vdocuments.mx/reader036/viewer/2022062500/5697bf7c1a28abf838c83d56/html5/thumbnails/7.jpg)
2. Debinding (450°C, 30min)
W-d50=4µm, SH-d50=12µm CP (600-50 MPa) W70-50%vol ; / W30%vol no CP, no SH
W-CuCrZr Single Layers*W
-Sk
ele
ton
full infiltration without cracks only possible:
3. Sintering ((1200°C, 60min in H2)
- at low heating rates (<10K/min) during 2, 3 and 4 (internal mismatch stress to be relaxed)
1. Cold Pressing (CP) + Space Holder (SH)
4. Infiltration (1200°C, 30min)
5. Hardening (ann.+ quenching 970°C-RT + aging at 480°C, 60min)
- in Vacuum (< 10-3 mbar) during 4 (Infiltration)
*S. Nawka et al., Proceedings of the PM2010 World Congress, 2010.
CuCrZrbad wetting behavior in Ar (CrxOy, ZrxOy, diffusion on surface)inhomog. precip. hard. in H2
EUROMAT 2011
![Page 8: Synthesis, characterization and FE-modeling of a W/CuCrZr FGM joint EUROMAT 2011 – Montpellier 12-15-09.2011 a IPP, Max-Planck-Institut für Plasmaphysik,](https://reader036.vdocuments.mx/reader036/viewer/2022062500/5697bf7c1a28abf838c83d56/html5/thumbnails/8.jpg)
W70-CuCrZr30(%vol)
W54CuCrZr46(%vol)
W31CuCrZr69(%vol)
W-CuCrZr Single Layers
EUROMAT 2011
![Page 9: Synthesis, characterization and FE-modeling of a W/CuCrZr FGM joint EUROMAT 2011 – Montpellier 12-15-09.2011 a IPP, Max-Planck-Institut für Plasmaphysik,](https://reader036.vdocuments.mx/reader036/viewer/2022062500/5697bf7c1a28abf838c83d56/html5/thumbnails/9.jpg)
1
Assembling the FGM Multilayer
W/wax ratio [vol%] P [MPa] Por [vol %]
97.3/3.7 500 30 (W70)
55/45 500 50 (W50)
100/0* - 70 (W30)
1 Cold Pressing
2 Debinding 3 Sintering
4 Infiltration 5 Hardening
10 mm
Close to zero porosity in ML (<0.1% on 80 mm²)
Residual porosity in CuCrZr
*Form tapping (n=50)
EUROMAT 2011
![Page 10: Synthesis, characterization and FE-modeling of a W/CuCrZr FGM joint EUROMAT 2011 – Montpellier 12-15-09.2011 a IPP, Max-Planck-Institut für Plasmaphysik,](https://reader036.vdocuments.mx/reader036/viewer/2022062500/5697bf7c1a28abf838c83d56/html5/thumbnails/10.jpg)
Synchrotron Tomography
W70%vol
W50%vol
W30%vol
Poster D12-P-2-05
Cooperation with ESRF, beamline ID-15
< 1% porosity on 10 mm³good homogeneity W50 / W70
1 mm
Spatial Res. Limit (WB at 100 KeV): 2.2µm/px
W high Z strong X-Ray absorption
![Page 11: Synthesis, characterization and FE-modeling of a W/CuCrZr FGM joint EUROMAT 2011 – Montpellier 12-15-09.2011 a IPP, Max-Planck-Institut für Plasmaphysik,](https://reader036.vdocuments.mx/reader036/viewer/2022062500/5697bf7c1a28abf838c83d56/html5/thumbnails/11.jpg)
W/CuCrZr Mechanical Properties 1
* G. Pintsuk. et al Fus. Eng. Design (2004)
*
** Cu 99.9-99.95%
**
EUROMAT 2011
Bending Test
![Page 12: Synthesis, characterization and FE-modeling of a W/CuCrZr FGM joint EUROMAT 2011 – Montpellier 12-15-09.2011 a IPP, Max-Planck-Institut für Plasmaphysik,](https://reader036.vdocuments.mx/reader036/viewer/2022062500/5697bf7c1a28abf838c83d56/html5/thumbnails/12.jpg)
W/CuCrZr Mechanical Properties 2
EUROMAT 2011
W30[%vol] W70[%vol]
Tensile Tests at different T
![Page 13: Synthesis, characterization and FE-modeling of a W/CuCrZr FGM joint EUROMAT 2011 – Montpellier 12-15-09.2011 a IPP, Max-Planck-Institut für Plasmaphysik,](https://reader036.vdocuments.mx/reader036/viewer/2022062500/5697bf7c1a28abf838c83d56/html5/thumbnails/13.jpg)
W/CuCrZr Thermal Properties
EUROMAT 2011
![Page 14: Synthesis, characterization and FE-modeling of a W/CuCrZr FGM joint EUROMAT 2011 – Montpellier 12-15-09.2011 a IPP, Max-Planck-Institut für Plasmaphysik,](https://reader036.vdocuments.mx/reader036/viewer/2022062500/5697bf7c1a28abf838c83d56/html5/thumbnails/14.jpg)
Image-based FEM*
Modeling Yielding and Failure at the Mesoscale
W30[%vol]
W30[%vol]
100 µm
Elongation and failure limits
Internal residual stress strongly influencing yielding and failure
EUROMAT 2011
![Page 15: Synthesis, characterization and FE-modeling of a W/CuCrZr FGM joint EUROMAT 2011 – Montpellier 12-15-09.2011 a IPP, Max-Planck-Institut für Plasmaphysik,](https://reader036.vdocuments.mx/reader036/viewer/2022062500/5697bf7c1a28abf838c83d56/html5/thumbnails/15.jpg)
FEM Macroscale: Residual Stress after Infiltration
possible damage in W
Avg plastic strain in single layersbelow failure limits
![Page 16: Synthesis, characterization and FE-modeling of a W/CuCrZr FGM joint EUROMAT 2011 – Montpellier 12-15-09.2011 a IPP, Max-Planck-Institut für Plasmaphysik,](https://reader036.vdocuments.mx/reader036/viewer/2022062500/5697bf7c1a28abf838c83d56/html5/thumbnails/16.jpg)
…varying h1, h2, h3
1. Residual stress (manufacturing ML+W-tile)
2. Thermal stress (steady-state operation ~ 10MW/m²)
FEM: Towards Optimization
Minimizing…
EUROMAT 2011
![Page 17: Synthesis, characterization and FE-modeling of a W/CuCrZr FGM joint EUROMAT 2011 – Montpellier 12-15-09.2011 a IPP, Max-Planck-Institut für Plasmaphysik,](https://reader036.vdocuments.mx/reader036/viewer/2022062500/5697bf7c1a28abf838c83d56/html5/thumbnails/17.jpg)
Minimizing Residual Stress after Infiltration
W30[%vol]
W70[%vol]
EUROMAT 2011
![Page 18: Synthesis, characterization and FE-modeling of a W/CuCrZr FGM joint EUROMAT 2011 – Montpellier 12-15-09.2011 a IPP, Max-Planck-Institut für Plasmaphysik,](https://reader036.vdocuments.mx/reader036/viewer/2022062500/5697bf7c1a28abf838c83d56/html5/thumbnails/18.jpg)
Max S: 513 MPa Max S: 611 MPa
S (Mises) [MPa]
W30W70
W-tile
CuCrZr
T [°C]
Mockup for High Heat Flux TestsW-tiles
CuCrZr
Joint
10.5 MW/m²
Opposite optimization trends: Infiltration vs Operation !
Minimizing Thermal Stress (Component Level)
EUROMAT 2011
![Page 19: Synthesis, characterization and FE-modeling of a W/CuCrZr FGM joint EUROMAT 2011 – Montpellier 12-15-09.2011 a IPP, Max-Planck-Institut für Plasmaphysik,](https://reader036.vdocuments.mx/reader036/viewer/2022062500/5697bf7c1a28abf838c83d56/html5/thumbnails/19.jpg)
Summary & Outlook
Future Steps
- Good strength and th.conductivity for the single compositions achieved
- Manufacturing of W-Tiles+3layers-FGM with percolating mesostructure and close-to-zero porosity ML shown
Mockup with optimized design + exp.
FATIGUE campaign (High Heat Flux
Test Facility GLADIS)
- “Upgrade” W/Cu W/CuCrZr successfully achieved while limiting the oxide formation and keeping good PH features
- Identification of two opposite design optimization trends (Infiltration vs Operation)
![Page 20: Synthesis, characterization and FE-modeling of a W/CuCrZr FGM joint EUROMAT 2011 – Montpellier 12-15-09.2011 a IPP, Max-Planck-Institut für Plasmaphysik,](https://reader036.vdocuments.mx/reader036/viewer/2022062500/5697bf7c1a28abf838c83d56/html5/thumbnails/20.jpg)
The authors are thankful to the Deutsche Forschungsgesellschaft (DFG)
for funding the project
Acknowledgement
T. Schubert, B.Kieback
J.Riesch, V.Pfaffenholz, M.Köppen, J.Du, F. Koch, G. Matern
M.di Michiel, M.Scheel
S.Nawka, F.Hennig
![Page 21: Synthesis, characterization and FE-modeling of a W/CuCrZr FGM joint EUROMAT 2011 – Montpellier 12-15-09.2011 a IPP, Max-Planck-Institut für Plasmaphysik,](https://reader036.vdocuments.mx/reader036/viewer/2022062500/5697bf7c1a28abf838c83d56/html5/thumbnails/21.jpg)
W70-CuCrZr30(%vol)
W54CuCrZr46(%vol)
W31CuCrZr69(%vol)
W-CuCrZr Multilayer
![Page 22: Synthesis, characterization and FE-modeling of a W/CuCrZr FGM joint EUROMAT 2011 – Montpellier 12-15-09.2011 a IPP, Max-Planck-Institut für Plasmaphysik,](https://reader036.vdocuments.mx/reader036/viewer/2022062500/5697bf7c1a28abf838c83d56/html5/thumbnails/22.jpg)
Alessandro Zivelonghi – EUROMAT 2011
Opposite trends: Infiltration vs Operation !
Max S: 676 MPa
2. Minimizing Thermal Stress during Operation
Max S: 513 MPa Max S: 611 MPa
S-Mises [MPa]
W30W70
W-tile
CuCrZr