High heat flux tests of the WENDELSTEIN 7-X pre-series target elements - experimental evaluation of the thermo-mechanical behaviour

The HHF testing of WENDELSTEIN 7-X pre-series target elements is an indispensable step in the qualification of the manufacturing process. The finally 890 divertor target elements are made of an actively water-cooled CuCrZr heat sink covered with flat tiles of CFC NB31 as plasma facing material. A set of 20 full scale pre-series elements was manufactured by PLANSEE to validate the materials and manufacturing technologies prior to the start of the series production. Due to the large mismatch in the coefficients of thermal expansion for CFC and CuCrZr - resulting in high residual stresses as well as high operation-induced stresses - the bonding zone between CFC and CuCrZr was detected to be the most critical issue for the operational behaviour of the target elements. To achieve a sufficiently high manufacturing quality together with a high lifetime during operation thermal testing of full scale mockups was performed in combination with extensive FEM analyses. In both cases heat loads were applied similar to the expected heat loads in W7-X. All pre-series elements were tested in the ion beam test facility GLADIS. The elements were tested with 100 cycles of 10 MW/m2 and several elements with even higher cycle numbers and heat loads up to 24 MW/m2. The instrumentation of the targets (thermocouples, strain gages) and the infrared camera observation of the heat loaded surface allow an experimental evaluation of the thermo-mechanical behaviour of the tested elements. The main result is a good agreement between experimental data and numerically computed predictions. Hot spots were, however, observed at the edges of several tiles during the HHF tests indicating local bonding problems. Therefore, a programme of fully 3D nonlinear thermal-mechanical FEM calculations was started to evaluate the thermo-mechanical behavior of the target elements with special focus on the optimization of the stress situation in the bonding zone between the CFC and the CuCrZr heat sink. This paper presents detailed results of the spatial and temporal temperature distributions, and their changes during the first 100 load pulses. In addition, measured and calculated strains are discussed. The measured temperatures and strains compared with FEM calculations confirm the chosen FEM approach. This allows a component optimisation to achieve a successful series production of the W7-X divertor target elements. (author)