Engineering topics

Hussain, Aftab

Publications and source records attributed to Hussain, Aftab.

4 records

DOE OSTI2023

Material Plasma Exposure eXperiment High Heat Flux Microwave Absorber Design, Manufacture, and Articles Test

The Material Plasma Exposure eXperiment (MPEX) at Oak Ridge National Laboratory is in the final design phase. MPEX will be capable of exposing neutron-irradiated materials to plasmas for the study of plasma-material interaction. This facility will provide information about the complex effects of plasmas on materials and contribute to examining new materials that can withstand high heat fluxes and high ion fluences for future fusion devices. MPEX plasma is heated by 70-GHz or 105-GHz electron Bernstein wave/electron cyclotron heating (ECH), and the high-frequency microwaves are prone to scattering microwave power, which can have detrimental effects, especially on diagnostic components. A large portion of the injected ECH power is expected to be absorbed by plasma, but the remainder requires that microwave absorbers be placed immediately upstream and downstream of the ECH launcher to minimize stray microwaves leaving the ECH region. These microwaves can inadvertently heat components that cannot be shielded or otherwise protected. The microwave absorber design is based on an array of pyramid-shaped ceramic tiles brazed to a water-cooled explosion-bonded heat sink and a stainless steel plate to produce one tile module. Computational fluid dynamics and structural analyses were performed to optimize and validate the design. Multiple test coupons were produced to validate the process for brazing the two different tile materials to the Glidcop AL-15 baseplate. The articles were tested to evaluate the reliability and thermal performance through exposure to an electron beam with a heat flux of up to 1.5 MW/m2. Nondestructive testing was performed before and after testing to identify voids or separations that may have been introduced by the high heat flux. This paper discusses the details of high heat flux microwave absorber design, manufacturing details and associated challenges, and test results, demonstrating the effectiveness of the proposed design.

Hussain, Aftab↗

DOE OSTI2023

Thermohydraulic Design Analysis of the Target Assembly in the Material Plasma Exposure Experiment Facility

The Material Plasma Exposure eXperiment (MPEX) project seeks to design a steady-state linear plasma facility at Oak Ridge National Laboratory that will be used to study plasma-material interactions (PMIs) at fusion prototypic levels, supporting the evaluation and development of materials for the next generation of fusion devices. This study is focused on PMI exposure of small-size neutron-irradiated specimens, which are clamped onto an actively cooled component. A thermohydraulic evaluation of a new MPEX target assembly design to assess the appropriate operation during MPEX operation is presented. To further guide the design and assess the structural integrity of the components under expected loads, preliminary thermomechanical stress analyses were also conducted. To ensure good thermal contact between the components, thermal interface materials, such as silver flexible graphite, were used in the assembly. It was found that the maximum target temperatures of 1572, 1463, and 1315 K were obtained for Grafoil thicknesses of 0.61, 0.38, and 0.25 mm, respectively. The distribution of the axial deformation at high heat fluxes showed that there are no gaps between components, indicating good contact at material interfaces. Moreover, the contact pressure between the target and other components indicated that very good contact was established at these interfaces. Furthermore, the stress-strain conditions for the target will be further used to assess the appropriate operation during MPEX experiments and gain insight into materials science phenomena during PMI experiments.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Final Design of the Material Plasma Exposure eXperiment

The Material Plasma Exposure eXperiment (MPEX) has completed its design phase. MPEX will be a unique facility to investigate plasma material interactions (PMIs) under fusion prototypic divertor conditions in steady state. This includes plasma exposure conditions expected in a fusion reactor divertor. Materials to be investigated will include solids, liquids, and neutron pre-irradiated materials. Electron and ion heating will allow for a large operational domain ranging from erosion-dominated PMI conditions to deposition-dominated PMI conditions. An overview of the final design for all MPEX systems is given. Here, in particular, it is shown how mission-driven project requirements have led to detailed design choices with innovative solutions. Examples are the water-cooled helicon window, the electron cyclotron heating launcher, the target holder and manipulator, and the autonomous decouplers.

Fusion reactor↗

DOE OSTI2022

Material Plasma Exposure eXperiment (MPEX) High Heat Flux Bellows for Component Alignment in High Microwave Environment

The Material Plasma Exposure eXperiment (MPEX) device is a linear plasma device developed to perform plasma material interaction experiments under the conditions prototypic of a fusion reactor divertor. MPEX has multiple systems that must be precisely aligned to the plasma axis, including an electron cyclotron heating system that emits up to 400 kW of microwave power into the vacuum vessel. Five distinct systems require precise alignment on the MPEX device, thus requiring four bellows, all of which are adjacent to the plasma at a relatively high heat flux of approximately 47 kW/m2 and microwave power regions. The MPEX high heat flux bellows (HHFB) is designed to deliver 6 degrees of freedom positioning. The HHFB includes titanium–zirconium–molybdenum (TZM) inserts that are brazed into a Glidcop AL-15 body using a high-temperature braze alloy, thus blocking direct line of sight to an edge-welded bellows from the plasma and microwave screen to block microwaves from the bellows. Further, a custom ConFlat knife edge is machined into the Glidcop AL-15, so the vacuum flanges do not need a braze or weld joint on the vacuum interface. Fingerstock or copper mesh is used to restrict microwave power from entering the interstitial space between the water-cooled Glidcop AL-15 body and edge-welded bellows. Glidcop AL-15 was selected as the material of choice for the water-cooled body because it can maintain mechanical integrity at elevated temperatures, and it also allows for a high-temperature braze. TZM was selected for its machinability and compatibility with vacuum and plasma requirements. A test article is also being considered for a similarly shaped component, the MPEX limiter, that will demonstrate the integrity of the braze joint under high thermal load. Results from this testing will be extrapolated to deduce the lifetime and integrity of the HHFB design.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗