Behavior of Brazed W/Cu Mockup Under High Heat Flux Loads

In order to transfer the heat from the armor to the coolant, tungsten has to be connected with a copper heat sink. The joint technology is the most critical issue for manufacturing plasma facing components. Consequently, the reliability of the joints should be verified by a great number of high-heat-flux （HHF） tests to simulate the real load conditions. W/Cu brazed joint technology with sliver free filler metal CuMnNi has been developed at Southwestern Institute of Physics （SWIP）. Screening and thermal fatigue tests of one small-scale fiat tile W/CuCrZr mockup were performed on a 60 kW electron-beam Material testing scenario （EMS-60） constructed recently at SWIP. The module successfully survived screening test with the absorbed power density （Pabs） of 2 MW/m2 to 10 MW/m2 and the following 1000 cycles at Pabs of 7.2 MW/m2 without hot spots and overheating zones during the whole test campaign. Metallurgy and SEM observations did not find any cracks at both sides and the interface, indicating a good bonding of W and CuCrZr alloy. In addition, finite element simulations by ANSYS 12.0 under experimental load conditions were performed and compared with experimental results.

High Heat Flux Testing of B_4C/Cu and SiC/Cu Functionally Graded Materials Simulated by Laser and Electron Beam

B4C, SiC and C, Cu functionally graded-materials (FGMs) have been developed by plasma spraying and hot pressing. Their high-heat flux properties have been investigated by high energy laser and electron beam for the simulation of plasma disruption process of the future fusion reactors, And a study on eroded products of B4C/Cu FGM under transient thermal load of electron beam was performed. In the experiment, SEM and EDS analysis indicated that B4C and SiC were decomposed, carbon was preferentially evaporated under high thermal load, and a part of Si and Cu were melted, in addition, the splash of melted metal and the particle emission of brittle destruction were also found. Different erosive behaviors of carbon-based materials (CBMs) caused by laser and electron beam were also discussed.

Manufacturing and High Heat Flux Testing of Brazed Flat-Type W/CuCrZr Plasma Facing Components

Water-cooled flat-type W/Cu Cr Zr plasma facing components with an interlayer of oxygen-free copper（OFC） have been developed by using vacuum brazing route.The OFC layer for the accommodation of thermal stresses was cast onto the surface of W at a temperature range of 1150oC-1200 oC in a vacuum furnace.The W/OFC cast tiles were vacuum brazed to a Cu Cr Zr heat sink at 940 oC using the silver-free filler material Cu Mn Si Cr.The microstructure,bonding strength,and high heat flux properties of the brazed W/Cu Cr Zr joint samples were investigated.The W/Cu joint exhibits an average tensile strength of 134 MPa,which is about the same strength as pure annealed copper.High heat flux tests were performed in the electron beam facility EMS-60.Experimental results indicated that the brazed W/Cu Cr Zr mock-up experienced screening tests of up to 15 MW/m^2 and cyclic tests of 9 MW/m^2 for 1000 cycles without visible damage.

Microchannel cooling technique for dissipating high heat flux on W/Cu flat-type mock-up for EAST divertor

As an important component of tokamaks,the divertor is mainly responsible for extracting heat and helium ash,and the targets of the divertor need to withstand high heat flux of 10 MW m-2 for steady-state operation.In this study,we proposed a new strategy,using microchannel cooling technology to remove high heat load on the targets of the divertor.The results demonstrated that the microchannel-based W/Cu flat-type mock-up successfully withstood the thermal fatigue test of 1000 cycles at 10 MW m^(-2)with cooling water of 26 l min^(-1),30°C(inlet),0.8 MPa(inlet),15 s power on and 15 s dwell time;the maximum temperature on the heat-loaded surface(W surface)of the mock-up was 493°C,which is much lower than the recrystallization temperature of W(1200°C).Moreover,no occurrence of macrocrack and‘hot spot’at the W surface,as well as no detachment of W/Cu tiles were observed during the thermal fatigue testing.These results indicate that microchannel cooling technology is an efflcient method for removing the heat load of the divertor at a low flow rate.The present study offers a promising solution to replace the monoblock design for the EAST divertor.

Evaluation of The Thermal Performance of Multi-Element Doped Graphite under Steady-State High Heat Flux

Multi-element doped graphite, GBST1308 has been developed as a plasma facing material (PFM) for high heat flux components of the HT-7U device. The thermal performance of the material under steady-state (SS) high heat flux was evaluated under actively cooling conditions, the specimens were mechanically joined to copper heat sink with supercarbon sheet as a compliant layer between the interfaces. The experiments have been performed in a facility of ACT (actively cooling test stand) with a 100 kW electron gun in order to test the suitability and the loading limit of such materials. The surface temperature and bulk temperature distribution of the specimens were investigated. The experimental results are very encouraging that when heat flux is not more than 6 MW/m2, the surface temperature of GBST1308 is less than 1000℃, which is the lowest, compared with IG-430U and even with CX-2002U (CFC); The primary results indicate that the mechanically-joined material system by such a proper design as thin tile, super compliant layer, GBST as a PFM and copper-alloy heat sink, can be used as divertor plates for HT-7U in the first phase.

Effect of Zr-Ti combined deoxidation on impact toughness of coarse-grained heat-affected zone with high heat input welding

In this study, the effects of Zr-Ti combined deoxidation and AI deoxidation on the impact toughness of coarse- grained heat-affected zone in high-strength low-alloy steels were investigated. More fine oxides were formed in the Zr-Ti-killed steel than in Al-killed steel. It was also found that more acicular ferrite grains were formed in the coarse-grained heat-affected zone in the Zr-Ti-killed steel than in Al-killed steel. The impact toughness of coarse-grained heat-affected zone of Zr-Ti-kiUed steel was higher than that of Al-killed steel. The good impact toughness was attributable to the pinning effect of fine oxides and the formation of acicular ferrite grains on fine oxides.

Probing microstructural evolution in weld metals subjected to varied CaF_(2)-TiO_(2) flux cored wires under high heat input electro-gas welding

Fused CaF_(2)-TiO_(2) fluxes have been designed,prepared,and applied in the flux cored wires to join EH36 shipbuilding steels under high heat input electro-gas welding.Ensuing microstructural evolution in the weld metals subjected to varied CaF_(2)-TiO_(2) flux cored wires has been fully documented.It has been demonstrated that as the content of TiO2 in the fused fluxes increases,columnar grain size increases,and major constituents in the weld metal change from lath bainite,to granular bainite,and then to acicular ferrite.Such phenomena are elucidated via salient chemical reactions involving oxygen pickup and concurrent titanium transfer.

Numerical Investigation of Jet Impingement Cooling with Supercritical Pressure Carbon Dioxide in a Multi-Layer Cold Plate during High Heat Flux

Jet impingement cooling with supercritical pressure carbon dioxide in a multi-layer cold plate during the heat flux of 400 W/cm_(2) is investigated numerically.The generation and distribution of pseudocritical fluid with the high specific heat of supercritical pressure carbon dioxide and the mechanism of the heat transfer enhancement led by the high specific heat are analyzed.For a given nozzle diameter,the effects of the geometric parameters of a multi-layer cold plate such as the relative nozzle-to-plate distance,relative plate thickness,and relative upper fluid thickness on the average heat transfer coefficient are studied.The results show that the target surface is cooled effectively with supercritical pressure carbon dioxide jet impingement cooling.When the radial distance is less than 6 mm,the maximum wall temperature is 368 K,which is 30 K lower than the maximum junction temperature for a silicon-based insulated gate bipolar transistor,a typical electronic power device.There is a pseudocritical fluid layer near the target surface,where specific heat reaches above 34 kJ/(kg·K)locally.The drastic rise of the specific heat leads to obvious heat transfer enhancement.Within a certain range,the local heat transfer coefficient and the specific heat are linearly correlated and Stanton number remains constant over this range.The heat transfer coefficient is at a maximum when the relative nozzle-to-plate distance is 1.As the relative plate thickness increases from 0.5 to 3.5 or the relative upper fluid thickness increases from 0.5 to 2.5,the average heat transfer coefficient decreases monotonically.

Numerical Analysis on Temperature Distribution in a Single Cell of PEFC Operated at Higher Temperature by1D Heat Transfer Model and 3D Multi-Physics Simulation Model

This study is to understand the impact of operating conditions, especially initial operation temperature (Tini) which is set in a high temperature range, on the temperature profile of the interface between the polymer electrolyte membrane (PEM) and the catalyst layer at the cathode (i.e., the reaction surface) in a single cell of polymer electrolyte fuel cell (PEFC). A 1D multi-plate heat transfer model based on the temperature data of the separator measured using the thermograph in a power generation experiment was developed to evaluate the reaction surface temperature (Treact). In addition, to validate the proposed heat transfer model, Treact obtained from the model was compared with that from the 3D numerical simulation using CFD software COMSOL Multiphysics which solves the continuity equation, Brinkman equation, Maxwell-Stefan equation, Butler-Volmer equation as well as heat transfer equation. As a result, the temperature gap between the results obtained by 1D heat transfer model and those obtained by 3D numerical simulation is below approximately 0.5 K. The simulation results show the change in the molar concentration of O2 and H2O from the inlet to the outlet is more even with the increase in Tini due to the lower performance of O2 reduction reaction. The change in the current density from the inlet to the outlet is more even with the increase in Tini and the value of current density is smaller with the increase in Tini due to the increase in ohmic over-potential and concentration over-potential. It is revealed that the change in Treact from the inlet to the outlet is more even with the increase in Tini irrespective of heat transfer model. This is because the generated heat from the power generation is lower with the increase in Tini due to the lower performance of O2 reduction reaction.

Flow Boiling of Ammonia in a Diamond-Made MicroChannel Heat Sink for High Heat Flux Hotspots

To solve the heat dissipation problem of electronic devices with high heat flux hotspots,a diamond microchannel heat sink consisting of 37 parallel triangular microchannels with channel lengths of 45 mm and hydraulic diameters of 280|im was designed.The flow boiling heat transfer characteristics of ammonia in the microchannels were investigated under high heat fluxes of 473.9-1000.4 W/cm^2.Saturated flow boiling experiments with saturation temperatures of 25℃,30℃,and 35℃ and mass fluxes of 98-1200 kg/m^2s were conducted,as well as subcooled flow boiling with inlet subcooling of 5℃ as a comparison.The temperature and pressure drop measurements were analyzed.The main conclusions below can be drawn.(1)At a given heat flux,the heat source temperature first decreased and then increased with the mass flux,and there existed an optimum mass flux to optimize the cooling performance of the heat sink.(2)The heat transfer performance under the saturated inlet condition was obviously better than that under the subcooled inlet condition.(3)A larger saturation temperature leaded to weakening of both the heat transfer capacity and the stability of the microchannel heat sink.Notably,with the high heat diffusion ability of the diamond substrate and the great heat transfer capacity of ammonia flow boiling in microchannels,the heat sink can achieve a heat removal capacity of up to 1000.4 W/cm^2.

Heterogeneous Microstructure-Induced Mechanical Responses in Various Sub-Zones of EH420 Shipbuilding Steel Welded Joint Under High Heat Input Electro-Gas Welding

Heterogeneous microstructure-induced mechanical responses in EH420 shipbuilding steel welded joint by electro-gas welding processed have been systematically studied by scanning electron microscopy,electron backscatter diffraction and mechanical testing.Comparing with the coarse-grained heat-affected zone(CGHAZ),the weld metal presents higher toughness(129.3 J vs.37.3 J)as it contains a large number of acicular ferrites with high-angle grain boundaries(frequency 79.2%)and special grain boundary∑3(frequency 55.3%).Moreover,coarse austenite grains in CGHAZ and slender martensite–austenite constituents between bainite laths may likely facilitate crack propagation.Polygonal ferrites and tempered pearlites formed at the junction of the fine-grained heat-affected zone and the intercritical heat-affected zone induced a softened zone with an average hardness of 185 HV0.5,which is the main reason for the occurrence of tensile fracture.

Critical Heat Flux(CHF)Correlations for Subcooled Water Flow Boiling at High Pressure and High Heat Flux

The subcooled water flow boiling is beneficial for removing the high heat flux from the divertor in the fusion reactor,for which an accurate critical heat flux(CHF)correlation is necessary.Up to now,there are many CHF correlations mentioned for subcooled water flow boiling in the open literatures.However,the CHF correlations’accuracies for the prediction of subcooled water flow boiling are not satisfactory at high heat flux and high pressure for reactor divertor.The present paper compiled 1356 CHF experimental data points from 15 independent open literatures and evaluated 10 existing CHF correlations in subcooled water flow boiling.From the evaluation,the W-2 CHF correlation performs best for the experimental CHF data in all existing critical heat flux correlations.However,the predicted mean absolute error(MAE)of the W-2 correlation is not very ideal for all database and the MAE of the W-2 correlation is from 30%to 50%for some database.In order to enhance the CHF prediction accuracy in subcooled water flow boiling at high heat flux and high pressure,the present paper developed a new CHF correlation.Compared with other existing CHF correlations,the new CHF correlation greatly enhances the prediction accuracy over a broad range of pressures and heat fluxes which are desired in the cooling of high heat flux devices,such as those in the fusion reactor divertor.The validation results show that the new correlation has a MAE of 10.05%and a root mean squared error(RMSE)of 16.61%,predicting 68.1%of the entire database within±10%and 81.5%within±15%.The MAE of the new CHF correlation is 7.4%less than that of the best existing one(W-2 correlation),further confirming its superior prediction accuracy and reliability.Besides,the new CHF correlation works well not only for a uniform power profile but also for a non-uniform power profile in subcooled water flow boiling at high pressure and high heat flux.

High heat flux thermal management through liquid metal driven with electromagnetic induction pump

In this paper, a novel liquid metal-based minichannel heat dissipation method was developed for cooling electric devices with high heat flux. A high-performance electromagnetic induction pump driven by rotating permanent magnets is designed to achieve a pressure head of 160 kPa and a flow rate of 3.24 L/min, which could enable the liquid metal to remove the waste heat quickly. The liquid metal-based minichannel thermal management system was established and tested experimentally to investigate the pumping capacity and cooling performance. The results show that the liquid metal cooling system can dissipate heat flux up to 242 W/cm2 with keeping the temperature rise of the heat source below 50°C. It could remarkably enhance the cooling performance by increasing the rotating speed of permanent magnets. Moreover, thermal contact resistance has a critical importance for the heat dissipation capacity. The liquid metal thermal grease is introduced to efficiently reduce the thermal contact resistance (a decrease of about 7.77 × 10−3 °C/W). This paper provides a powerful cooling strategy for thermal management of electric devices with large heat power and high heat flux.

Influence of recrystallization on tungsten divertor monoblock under high heat flux

Extremely high heat flux reaching 20 MW·m^(−2) can be foreseen for the future fusion reactor.Such high heat flux would induce recrystallization of tungsten(W)material,leading to significant strength loss of tungsten material and increment of ductility at high temperature,in particular when the temperature is much higher than its ductile-to-brittle transition temperature(DBTT).In this paper,an International Thermonuclear Experimental Reactor(ITER)-like tungsten divertor monoblock is modeled,and benchmark has been done first to get consistent results with ITER.Then,the monoblock structure has been optimized in order to get a lowest possible temperature and stress during heating and cooling phase separately compared to the baseline structure.Structural analysis of two kinds of states:stress-relieved tungsten and recrystallized tungsten using finite element method has been performed,aiming at finding out the recrystallization impact on the mechanical behavior of tungsten in divertor monoblock under cyclic high heat flux.Damages due to progressive deformation and time-independent fatigue lifetime of these two states of tungsten have been assessed and compared according to criteria The Structural Design Criteria for ITER In-vessel Components.Finally,the impact of different material recrystallization temperature on mechanical behavior has been explored under stationary heat load.The result shows that after recrystallization,thermal stress of tungsten material can be released by the larger plastic deformation compared to the stress-relieved tungsten.However,it is easier for recrystallized tungsten to get damaged due to progressive deformation as well as fatigue under 20 MW·m^(−2) cyclic heat flux than stress-relieved tungsten because of its relatively lower yield strength and larger plastic strain,which would cause low-cycle strain fatigue.Furthermore,tungsten with lower recrystallization temperature distorts more seriously,and therefore,it can be predicted the cracks would be initiated more easily.

A review of soldering by localized heating

In recent years,the rapid development of the new energy industry has driven continuous upgrading of high-density and high-power devices.In the packaging and assembly process,the problem of differentiation of the thermal needs of different modules has become increasingly prominent,especially for small-size solder joints with high heat dissipation in high-power devices.Localized soldering is con-sidered a suitable choice to selectively heat the desired target while not affecting other heat-sensitive chips.This paper reviews several local-ized soldering processes,focusing on the size of solder joints,soldering materials,and current state of the technique.Each localized solder-ing process was discovered to have unique characteristics.The requirements for small-size solder joints are met by laser soldering,microres-istance soldering,and self-propagating soldering;however,laser soldering has difficulty meeting the requirements for large heat dissipation,microresistance soldering requires the application of pressure to joints,and self-propagating soldering requires ignition materials.However,for small-size solder junctions,selective wave soldering,microwave soldering,and ultrasonic soldering are not appropriate.Because the magnetic field can be focused on a tiny area and the output energy of induction heating is large,induction soldering can be employed as a significant trend in future research.

On the heterogeneous microstructure development in the welded joint of 12MnNiVR pressure vessel steel subjected to high heat input electrogas welding

Microstructure features of 12 MnNiVR pressure vessel steel welded joint deposited by the high heat input electrogas welding have been systematically investigated. It is revealed that the welded joint is featured by a heterogeneous juxtaposition. The coarse grained heat-affected zone(CGHAZ) primarily consists of lath bainites and minor granular bainites. The fine grained heat-affected zone(FGHAZ) is dominated by polygonal ferrites, pearlites, and fine cementite particles. Moreover, electron backscatter diffraction results further demonstrate that the CGHAZ is populated by coarse prior austenite grains(PAGs) with high frequency(61.3%) of low angle grain boundaries(LAGBs). On the other hand, the FGHAZ is filled with fine PAGs with a lower frequency(19.6%) of LAGBs. Such microstructural differences may likely contribute to differed mechanical properties for samples tested at designed positions.

INFLUENCE OF HEAT TREATMENT ON OXIDATION PROPERTIES OF C/C COMPOSITES FABRICATED BY HIGH PRESSURE IMPREGNATION CARBONIZATION

Felt base carbon/carbon composites fabricated by super-high pressure impregnation carbonization process (SPIC) were heat treated at high temperature 2773K. The oxidation properties of felt base carbon/carbon composites were investigated at different temperatures (773-1173K), and the microstructures of carbon/carbon composites were studied by SEM and X-ray diffraction. The experimental results showed that the inter-laminar distance of (002) plane (d002) deceased while the microcrystalline stack height (Lc) increased. The oxidation rate of felt base carbon/carbon composites was invari-able at certain temperatures. The oxidation mechanism of carbon/carbon composites changed remarkably at the oxidation temperature 973K. At the initial oxidation stage of carbon/carbon composites, carbon matrix was oxidized much more rapidly than carbon felt.

Effects of abnormally high heat stress on petroleum in reservoir——An example from the Tazhong 18 Well in the Tarim Basin

An igneous intrusion of 94m thick was discovered intruding into the Silurian sandstone from Tazhong 18 Well. The petroleum previously preserved in the Silurian sandstone reservoir was altered into black carbonaceous bitumen by abnormally high heat stress induced by the igneous intrusion. The reflec-tance of the carbonaceous bitumen reaches as high as 3.54%, indicating that the bitumen had evolved into a high thermal evolution level. Similar to the Silurian samples from the neighboring Tazhong 11, Tazhong 12, Tazhong 45 and Tazhong 47 wells, the distribution of C27, C28 and C29 steranes of the car-bonaceous bitumen is still "V" -shaped and can still be employed as an efficient parameter in oil source correlation. The "V" -shaped distribution indicates that the hydrocarbons from the Tazhong 18 and the neighboring wells were all generated from the Middle-Upper Ordovician hydrocarbon source rocks. However, the oil source correlation parameters associated with and terpanes had been changed greatly by the high heat stress and can no longer be used in oil source correlation. The δ 13C values of the pe-troleum from the neighboring wells are between -32.53‰ and -33.37‰, coincident with those of the Paleozoic marine petroleum in the Tarim Basin. However, the δ 13C values of the carbonaceous bitumen from the Tazhong 18 Well are between -27.18‰ and -29.26‰, isotopically much heavier than the pe-troleum from the neighboring wells. The content of light hydrocarbons (nC14-nC20) of the saturated hydrocarbon fraction in the carbonaceous bitumen is extremely higher than the content of heavy hy-drocarbons. The light/heavy hydrocarbon ratios (ΣnC21-/ΣnC22+) are between 4.56 and 39.17. In the saturated fraction, the even numbered hydrocarbons are predominant to the odd numbered, and the OEP (Odd to Even Predominance) values are between 0.22 and 0.49. However, the content of light hy-drocarbons in the petroleum from the neighboring wells is relatively low and the content of the even numbered hydrocarbons is almost equal to that of the odd numbered. Compared with the samples from the neighboring wells, the abundance of non-alkylated aromatic hydrocarbons, such as phenanthrenes, and polycyclic aromatic hydrocarbons (PAHs), such as fluoranthane, pyrene, benzo[a]anthracene and benzofluoranthene, are relatively high.

Design of Tokamak ELM Coil Support in High Nuclear Heat Environment

In Tokomak, the support of the ELM coil, which is close to the plasma and subject to high radiation level, high temperature and high magnetic field, is used to transport and bear the thermal load due to thermal expansion and the alternating electromagnetic force generated by high magnetic field and AC current in the coil. According to the feature of ITER ELM coil, the mechanical performance of rigid and flexible supports under different high nuclear heat levels is studied. Results show that flexible supports have more excellent performance in high nuclear heat condition than rigid supports. Concerning thermal and electromagnetic （EM） loads, optimized results further prove that flexible supports have better mechanical performance than rigid ones. Through these studies, reasonable support design can be provided for the ELM coils or similar coils in Tokamak based on the nuclear heat level.