thermo-mechanical analyses and design of components for ... · 1 consorzio rfx, euratom-enea, corso...
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INTRODUCTION
TOROIDAL SUPPORT STRUCTURE MODIFICATIONS
Thermo-mechanical analyses and design of components for fusion devices
1 Consorzio RFX, EURATOM-ENEA, Corso Stati Uniti 4, I-35127 Padova, Italy
N.Patel1, M.DallaPalma1, P.Sonato1
MotivationFull exploitation of RFX-mod sought upgrade of machine,� To improve passive MHD control by bringing passive copper shell as near as
possible to plasma (Reduced plasma-shell distance)� To minimize braking torque on plasma through the elimination of vacuum vessel
(Improve wall lock mode scenario)
Major mechanical modifications foreseen� Remove vacuum vessel and make Toroidal Support Structure (TSS) as new
vacuum bounday
� Design support of passive Cu-shell� Design support of FW tiles� Assembly and sensor cable routing
RFX ----> RFX-mod ----> RFX-mod2
1992
to
1999
2004
to
till now
Concept and
planning
phase
Major Radius, R(m) 2
Minor Radius, a(m) 0.5
R a
Supporting ring
TSS
Saddle coils
Vacuum vessel
Cu shellFW tiles
Requirements� Maintain UHV vacuum level
(10-8 mbar)
� Modifications in view of present TSS structure� To Provide vacuum sealing on toroidal and poloidal cuts� To provide electrical insulation at 3 cuts
� Attach vacuum ports on TSS� To close all holes and openings
Poloidal joint
�Vacuum sealing
�Electrically insulated
�Mechanical continuity
Internal toroidal joint
�Vacuum sealing
�Electrically insulated
External toroidal joint
�Vacuum sealing
�electrically continuity due to the
geometrical complexity
Welded configuration
Resistive plate weld configuration
Braze-weld configuration
Types of openings:I. Ports openings (151)
II. Support openings (24x2)
III. Poloidal bolt openings (24x2)
IV. Assembly centering holes (4)
Summary of modifications
Sr. TSS Qty. Modification
1 Int. eq. ports 7 To be closed
2 Ext. eq. ports 22 To be integrated
3 Vertical Ports 122 To be integrated
TSS support To be closed from inner
CeramicWeld plate
PASSIVE COPPER SHELL AND SUPPORT STRUCTURE
Euratom-ENEA
Association
Main constraints� Varying thickness of sealing surface
(Max. 47 mm to Min. 20 mm)
� Non-flat sealing surface (Ports at outer toroidal cut)
� Sealing surfaces crosses/intersecting each other
� Only 5 mm gap (Sealing + Insulation)
� No feasibility of flange connection
(Only connection options are, Clamping rings at
toroidal cuts and Bolted connection at poloidal cuts)
� Assembly sequence will be changed
� Considered at external
toroidal cut as most suitable
solution to accommodate
ports
� Weld at inner surface (No
trapped air)
� Minimum machining required
to prepare weld leaps
Weld lip
SS plate
� Resistive plate full weld:
� 200 mm long resistive metal plate
(Nichrome, Constantan) can be
welded to top and bottom TSS
� A plate made of electrical
insulating material (G10, ceramic)
between top and bottom TSS
�Braze-weld solution: need gap of around
50 mm to accommodate the joint
�welding solution:
�The equatorial sealing will be closed with
a cylindrical plate, which will be welded to
the resistive plate and to the poloidal cut
at the TSS
�Brazing solution:
�Cylindrical sealing plate will be brazed to
ceramic plate at both side which will be
welded to other cylindrical plate
�Mechanical stiffness:
�Toroidal continuity at poloidal joints will be
provided by bolted junctions electrically
insulated with G10/ceramic spacers and
bushes
4
TSS support
openings 48
To be closed from inner
side
5
Poloidal bolt
openings 48
To be closed from inner
side
6
Assembly
centering holes 4 To be closed
7 Poloidal cut 2 Braze-weld
8 Ext. toroidal cut 1 Full welded
9 Int. toroidal cut 1 Resistive weld plate
TSS Analysis
A. Max.= 298 MPA
C. Max.= 99 MPaB. Max.= 298 MPA
D E
B C
D
E
A. Max. = 0.4 mm
C. Max. = 0.4 mmB. max. total = 0.4 mm
D. Max. = 0.3 mm E. Max. = 0.25 mm
B
C
D
E
Free studVertical supporting stud
FW tile support concepts
R=1995 mm
511.5 mm
493.6 mm
Washer of 0.5
mm to 5mm
thickness
FW key fastner
Bonded to shell
Thk. Min= 1 mm
Thk. Max.= 3 mm
RFX-mod
Cu shell
m/c major axis
Plasma
center
Side thick element is for
vertical alignment of tile
Element: solid278
Element: Link33
Shell support
element
Temp = 294° K
Plasma flux
� 20 MJ of energy dissipated on FW (1.8 MW/m2)
� Pulse duration: 310 ms
� 20 min cooling between pulses
� Total 30 pulses considered for analysis
� At support 301 K temp. applied
� Radiation heat transfer is not included
Temp. distribution and mechanical behavior
Section - AA
Bottom_shell
Top_shell
BS_near_
support
Max. = 450 K Min. = 300 K
Plasma heat flux
Copper shell
Tile
Key
Supporting
washer
In-Washer
Heat conduction path
local displacements
Equivalent stresses
Due to change of vacuum boundary in RFX-mod2,
major change in internal systems will be,
� To design new support system for Cu-shell and
FW tiles
� As FW tiles will come nearer to Cu-shell, temp.will increase in Cu-shell.
Above model describe the concept of FW tile
support on Cu-shell.
Temp. distribution considering this configuration is
studied using FEA simulation as shown here.
Also structural study is going on for shell supporton TSS considering temp. distribution obtain by
FEA results.
Results shown that are within acceptable limit of
geometry displacement.
Results for equivalent stresses shows stress
concentration on single node due to coarse mesh at
support region which can be neglect.