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.

Heat Transfer Characteristics of a Microchannel Heat Sink with Highly-Dense Micro-Jet Arrays

This paper proposed a new structure of highly-dense micro-jet arrays for hybrid jet-impingement/microchannel heat sinks(~120 jet per cm^(2) with jet width of 0.35 mm).Parametric study is performed to investigate the influence of structure and flow parameters on the convective heat transfer of water jet cooling in confined space.The simulation results show that the optimal jet width,jet spacing and impingement distance are around 0.2 mm,0.2 mm and 0.3 mm,respectively,which can achieve a low thermal resistance as well as a relatively low pressure drop.The analysis of the heat transfer pathways shows that the micro-fin jet structures can extend the impinging heat transfer area and conduct a considerable proportion of heat,which can reach up to 38.9%with the Reynolds number ranging from 797.1 to 5602.2.The heat transfer characteristics in the heat sink will shift from impingement dominated heat transfer to the channel-convection dominated heat transfer as the jet impingement distance increases.A correlation is proposed to predict the average Nusselt number on the stagnation area for the heat sink with different structure parameters,and the deviations of predictions from the numerical results are less than 10%.

Application and prospect of the fluid cooling system of solar arrays for probing the Sun

The Solar Close Observations and Proximity Experiments(SCOPE)mission,which has been proposed by the Yunnan Observatories,Chinese Academy of Sciences,aiming to operate at a distance of 5 to 10 solar radii from the Sun,plans to complete the in situ detection of the solar eruption process and observation of the magnetic field structure response.The solar flux received by the satellite ranges from 10^(3) to 10^(6) Wm^(-2),which poses challenges for thermal management of the solar arrays.In this work,the solar array cooling system of the Parker Solar Probe is discussed,the developments of the fluid loop technique are reviewed,and a research plan for a next-generation solar array cooling system is proposed.This paper provides a valuable reference for novel thermal control systems in spacecraft for solar observation.

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.

Thermal performance of a single-layer packed metal pebble-bed exposed to high energy fluxes

It is difficult to accurately measure the temperature of the falling particle receiver since thermocouples may directly be exposed to the solar flux.This study analyzes the thermal performance of a packed bed receiver using large metal spheres to minimize the measurement error of particle temperature with the sphere temperature reaching more than 700°C in experiments in a solar furnace and a solar simulator.The numerical models of a single sphere and multiple spheres are verified by the experiments.The multiple spheres model includes calculations of the external incidence,view factors,and heat transfer.The effects of parameters on the temperature variations of the spheres,the transient thermal efficiency,and the temperature uniformity are investigated,such as the ambient temperature,particle thermal conductivity,energy flux,sphere diameter,and sphere emissivity.When the convection is not considered,the results show that the sphere emissivity has a significant influence on the transient thermal efficiency and that the temperature uniformity is strongly affected by the energy flux,sphere diameter,and sphere emissivity.As the emissivity increases from 0.5 to 0.9,the transient thermal efficiency and the average temperature variance increase from 53.5%to 75.7%and from 14.3%to 27.1%at 3.9 min,respectively.The average temperature variance decreases from 29.7%to 9.3%at 2.2 min with the sphere diameter increasing from 28.57 mm to 50 mm.As the dimensionless energy flux increases from 0.8 to 1.2,the average temperature variance increases from 13.4%to 26.6%at 3.4 min.

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.

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.

An investigation on application potentiality of microstructure heat sinks with different flow topological morphology

Microstructure heat sinks have great potential for high heat flux cooling.In this paper,we compared microchannel(MC),micro-pin-fin(MPF),manifold microchannel(MMC),and manifold micro-pin-fin(MMPF)heat sinks to figure out the pros and cons.Fluid flow and manifold unit models are used to study thermal and hydrodynamic performance.The heat sinks with different channel/fin sizes,manifold numbers,and porosities are discussed according to the pressure drop,temperature,thermal resistance,and coefficient of performance.Results show that MMC and MMPF heat sinks are superior to MC and MPF heat sinks,and there are also differences between MMC and MMPF heat sinks.Typically,the MMPF heat sink has lower maximum temperature,temperature non-uniformity,and total thermal resistance R_(tot).In contrast,the MMC heat sink has a lower pressure drop and higher COP.For the MMPF heat sink,at the nozzle width of 6.75μm and the MPF width of 70.71μm(porosity=0.167),it achieves the lowest total thermal resistance of R_(tot)=2.97×10^(-6)K m^(2)/W.Under 10^(3)W/cm^(2)heat flux,the maximum surface temperature rise is 29.74 K,and the maximum temperature difference of the heating surface is 3.15 K.This research initially provides a clear reference on the selection of single-phase cooling microstructures for ultra-high heat flux dissipation.

Numerical Investigation on Convective Heat Transfer of Supercritical Carbon Dioxide in a Mini Tube Considering Entrance Effect

There are more and more researches on heat transfer characteristics and prediction of supercritical CO_(2).The method of adding adiabatic section before and after heating section is usually adopted in these researches to ensure that the fluid entering the heating section is no longer affected by boundary layer,but the appropriate length range of adiabatic section and the influence of entrance effect are not discussed.However,some studies show that the entrance effect would affect the heat transfer in mini tubes.This paper uses the commercial CFD code FLUENT 19.0 to numerically study the heat transfer of supercritical CO_(2) in a mini tube under different working conditions(such as Re_(in),P_(in),q_(w) and flow direction)and the lengths of the adiabatic section(l_(as)/d).The entrance effects on heat transfer is more pronounced when Re_(in) is within the transition state and wall heat flux is relatively high,the resulting heat transfer deterioration causes T_(w,x) and h_(w,x) to rise sharply.As the adiabatic section increases,the location at which the heat exchange deteriorates moves to the entrance of the heating section and eventually leaves.The buoyancy effect and flow acceleration effect caused by the sharp change of physical properties are analyzed,and the dimensionless velocity distribution at the inlet of the heating section in different adiabatic sections is compared.It is proved that the entrance effect has an influence on the convection heat transfer of supercritical CO_(2) in mini tubes.The interaction reflected by wall shear stress between boundary layer development and drastic changes in physical properties is the cause of heat transfer deterioration.

Ground experimental investigations into an ejected spray cooling system for space closed-loop application

Spray cooling has proved its superior heat transfer performance in removing high heat flux for ground applications. However, the dissipation of vapor liquid mixture from the heat sur- face and the closed-loop circulation of the coolant are two challenges in reduced or zero gravity space enviromnents. In this paper, an ejected spray cooling system for space closed-loop application was proposed and the negative pressure in the ejected condenser chamber was applied to sucking the two-phase mixture from the spray chamber. Its ground experimental setup was built and exper- imental investigations on the smooth circle heat surface with a diameter of 5 mm were conducted with distilled water as the coolant spraying from a nozzle of 0.51 mm orifice diameter at the inlet temperatures of 69.2 ℃ and 78.2 ℃ under the conditions of heat flux ranging from 69.76 W/cm2 to 311.45 W/cm2, volume flow through the spray nozzle varying from 11,22 L：h to 15.76 L·h. Work performance of the spray nozzle and heat transfer performance of the spray cooling system were analyzed; results show that this ejected spray cooling system has a good heat transfer performance and provides valid foundation for space closed-loop application in the near future.

Thermal Shock Behavior Analysis of Tungsten-Armored Plasma-Facing Components for Future Fusion Reactor

In a fusion reactor, plasma-facing components（PFCs） will suffer severe thermal shock; behavior and performance of PFCs under high heat flux（HHF） loads are of major importance for the long-term stable operation of the reactor. This work investigates the thermo-mechanical behaviors of tungsten armor under high heat loads by the method of finite element modeling and simulating. The temperature distribution and corresponding thermal stress changing rule under different HHF are analyzed and deduced. The Manson–Coffin equation is employed to evaluate the fatigue lifetime（cyclic times of HHF loading） of W-armored first wall under cyclic HHF load. The results are useful for the formulation design and structural optimization of tungsten-armored PFCs for the future demonstration fusion reactor and China fusion experimental thermal reactor.