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Principal Investigator: Brian Williams, Ultramet Design and Modeling Support:

Department of Energy SBIR Phase I: Advanced Tungsten Structures for Plasma-Facing Components in Magnetic Confinement Fusion Energy Reactors. Principal Investigator: Brian Williams, Ultramet Design and Modeling Support: Dr. Nasr Ghoniem, Digital Materials Solutions

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Principal Investigator: Brian Williams, Ultramet Design and Modeling Support:

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  1. Department of Energy SBIR Phase I:Advanced Tungsten Structures for Plasma-Facing Components in MagneticConfinement Fusion Energy Reactors Principal Investigator: Brian Williams, Ultramet Design and Modeling Support: Dr. Nasr Ghoniem,Digital Materials Solutions Dr. Shahram Sharafat, Digital Materials Solutions Design and Test Support Dr. Dennis Youchison, Sandia National Laboratories Program Duration: 9 Months, Starting June 27, 2005

  2. The primary objective of this project is to develop and demonstrate the initial feasibility of innovative refractory materials and structures that will allow for extended fusion energy system steady-state operation at heat flux levels greater than 15 MW/m2 and be capable of surviving brief excursions to 1 MJ/m2. Program Goal

  3. Approach & Potential Design Benefits • Ultramet will fabricate an ultrahigh temperature heat • exchanger composed of a thin tungsten shell integrally • bonded to an open-cell tungsten foam core, which will • provide both the primary mechanical structure and • extremely efficient coolant channels for thermal control of • critical components. • Less Complex: Foam structure is inherently porous, therefore no intricate and expensive machining of coolant passages is required. • Heat Transfer: W Foam heat exchanger is metallurgically bonded to the solid CVD W hot wall for optimal heat transfer. • Durability: High stiffness, W foam structures have greater resistance to mechanical and thermal shock than solid W. SEM micrograph of 100-ppi tungsten foam

  4. Task 1: Thermomechanical Modeling - Performed by DMS to establish thermomechanical durability and heat transfer characteristicsfor use in planning and analyzing high heat flux experiments at Sandia. Task 2: Heat Exchanger Fabrication - Tungsten foam/tungsten shell composite heat exchangers (nominally 6-8“ long × 0.5" diameter) will be fabricated by Ultramet based on the properties defined in Task 1. - Materials Characterization at Ultramet: SEM, EDS, XRD Task 3: High Heat Flux Testing and Analysis - The tungsten heat exchangers will be tested in the 30-kW electron beam test system (EBTS) at Sandia using helium coolant. A thermal response curve will be generated illustrating surface temperature vs. input power at various mass flow rates, from which the effective heat transfer will be determined. Task 4: Reporting Phase I Statement of Work (6/27/05-3/26/06):

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