Haruyuki Murakami

The Manufacturing of the Superconducting Magnet System for the JT-60SA

JT-60SA is the satellite tokamak for ITER in the Broader Approach agreement. The JT-60SA uses 18 toroidal field coils, a central solenoid with 4 modules, and 6 equilibrium field coils, they are all superconducting coils with forced flow cooled conductors. All detailed designs of these superconducting coils have been completed. The manufacturing of conductors and coils are progressing in Japan and EU. This paper shows the latest manufacturing activities and final design adjusting of its magnet system and their utilities.

Numerical Simulation of the Critical Current and n-Value in

To demonstrate the applicability of Nb3Sn Cable in Conduit Conductors (CICCs) to International Thermonuclear Experimental Reactor (ITER) coils, four Nb3Sn model coils have been constructed and tested. The experimental results showed that the measured critical current of the conductors degraded compared with what is expected from the ability of the strands. In addition, the larger is the applied electromagnetic force, the larger the magnitude of the degradation is. A degradation in n-value was also observed. One of the explanations of this degradation is supposed to be a local strand bending. This consideration has been supported by test results, in which a similar degradation in the critical current and n-value was observed when applying periodic bending strains to a single strand. However, general dependence of critical current on periodic bending strain has not been clarified in this test since the experiments were carried out at a certain magnetic field, temperature and strain. Therefore, a numerical simulation code was developed to study the general dependence of the critical current and n-value of Nb3Sn strand on periodic bending strain. A distributed constant circuit model is applied to simulate current transfer among the filaments in the strand. The simulation results show relatively good agreement with the experimental results but some modification in modeling is required for more accurate simulation

rm Nb_3rm Sn

The critical current performance of a large Nb3Sn cable-in-conduit conductor (CICC) was degraded by periodic bending of strands due to a large transverse electromagnetic force. The degradation of each strand due to this bending should be evaluated in calculations of the critical current of a CICC, but a suitable model has not been developed yet. Therefore, the authors have developed a new analytical model which takes into account plastic deformation of copper and bronze and filament breakage. The calculated results were compared with test results for uniformly bent Nb3Sn bronze-route strands. The calculated results assuming a high transverse resistance model (HTRM) show good agreement with the test results, a finding which confirms the validity of the model. Because of a much shorter calculation time than for numerical simulation, the developed model seems much more practical for use in calculating the critical current performance of a Nb3Sn CICC. In addition, simulation results show that since the neutral axis of a bent strand shifts to the compressive side due to plastic deformation of the copper and bronze, and/or filament breakage, the strand is elongated by bending. This elongation may enhance the strands critical current performance. Moreover, the calculated results indicate that the dependence of the critical current on the bending strain is affected by the bending history if the strand is excessively bent, especially when filaments are broken. In a real magnet, since a strand in a CICC is normally subject to the maximum electromagnetic force prior to an evaluation of its performance at a lower electromagnetic force, the effect of over-bending should be taken into account in calculations of its critical current performance, especially when filament breakage occurs.

Strand Subjected to Bending Strain

A central solenoid (CS) model coil (CSMC) was manufactured by using real manufacturing jigs and procedure to validate the CS manufacturing processes for JT-60SA. The winding accuracy and the temperature control precision during the heat treatment met the requirements. The vacuum pressure impregnation process was also successfully finished. The cold test of the CSMC was performed as a final check of the manufacturing process. The joint resistance, the Ic, and the pressure drop measurements were conducted as the verification test. The results of verification test satisfied the design requirements. These results indicate that the manufacturing processes of the JT-60SA CS has been established. The manufacturing of real CS pancakes just started after finishing the CSMC test.

Analytical model of the critical current of a bent Nb3Sn strand

Several components for central solenoid (CS) of JT-60 Super Advanced (JT-60SA) were newly developed and tested. The butt-type joint, the electrical resistance of which is about 2 nΩ, was developed to increase the winding diameter. The insulation system, which consists of Glass/Kapton/Glass tape and Bisphenol A diglycidyl ether (DGEBA) epoxy, showed sufficient tensile strength after the irradiation of 100 kGy. Insulation characteristics of 4 × 4 winding stack sample after the compression of 705 kN 36 000 times was able to withstand voltages larger than 21 kV. The heat treatment and transfer of the CS model coil with superconductor were conducted. The pancake temperature during flat top was maintained at 923 ± 4 K. The maximum temperature difference in the pancake was 30 K. All manufacturing processes were confirmed so that the mass production of CS will be started in 2013.

Development and Test of JT-60SA Central Solenoid Model Coil

JT-60SA is foreseen in the Broader Approach Agreement as the satellite tokamak for ITER. It uses 18 toroidal field coils, a central solenoid with four modules, and six equilibrium field coils. The coils are all superconducting with forced-flow cooled conductors. Series production of conductors and coils is progressing in Japan and Europe. This paper shows the latest manufacturing activities of the magnet system and its utilities.

Development of Central Solenoid for JT-60SA

PA (procurement arrangement) for poloidal field (PF) coil system, which consists of the central solenoid (CS) and the equilibrium field (EF) coils, was agreed between Japan and EU. During this activity, design of PF coils system was continued to be modified. For CS, material for the jacket of this conductor was changed into stainless steel (316LN) to make providing easier. In the modified material, maximum stress at the jacket was kept within the allowable limit. Accompanying this modification, the amount of pre-compress had to be re-estimated. Therefore, it was clarified that designs of pre-compression and tie plates need not to be major modification. For EF coils, positions and the number of turns were modified since the progress of the research for the plasma operations required in JT-60SA. Due to this optimization, total amount of superconducting material was reduced. The detail designs of PF coils were also performed to reduce the materials of supports and to evaluate the mechanical strength considering the various events. Thickness of clamp plate of the EF coil which received relatively small electromagnetic force was able to be reduced. Regarding the design of support legs with flexible plate, deformation of toroidal field (TF) coil was considered that should be included the evaluation of stress at this parts because this parts are directly attached on the TF coil case. Therefore, the revised designs of supports with sufficient mechanical strength were obtained for EF1 and EF4.

Mass Production of Superconducting Magnet Components for JT-60SA

Manufacture of poloidal field (PF) coil system in JT-60SA is progressing. Recently, fabrication of the winding machines for equilibrium field (EF) coils and central solenoid (CS) were completed and the winding with the superconducting conductor was started for an EF coil (EF4). A few double pancake (DP) coils for EF4 were fabricated, and it was realized that the error of circularity for DP coils became less than the designed value. Design of the conductor end structure was also progressed. This part had the role of restraining the conductor end to prevent its separation from the winding pack. It was confirmed by the structural analysis that the conductor end structure for CS, which receives the large electromagnetic (EM) force, had sufficient mechanical strength. It was also checked by the cold test that this structure satisfied the designed performance for the electrical isolation in addition to the mechanical performance. Regarding the design of the inlet for CS, mechanical reinforcement was considered for its structure. Final design of CS inlet was determined by structural analysis to confirm the sufficient mechanical strength against the vertical compression induced by EM forces.

Recent Progress of the Design Activity for the Poloidal Field Coil System in JT-60SA

In the framework of the JT-60SA project, aiming at upgrading the present JT-60U tokamak toward a fully superconducting configuration, the detailed design phase led to adopt for the three main magnet systems a brand new design. Europe (EU) is expected to provide to Japan (JA) the totality of the toroidal field (TF) magnet system, while JA will provide both Equilibrium field (EF) and Central Solenoid (CS) systems. All magnet designs were optimized trough the past years and entered in parallel into extensive experimentally-based phases of concept validation, which came to maturation in the years 2009 and 2010. For this, all magnet systems were investigated by mean of dedicated samples, e.g. conductor and joint samples designed, manufactured and tested at full scale in ad hoc facilities either in EU or in JA. The present paper, after an overall description of magnet systems layouts, presents in a general approach the different experimental campaigns dedicated to qualification design and manufacture processes of either coils, conductors and electrical joints. The main results with the associated analyses are shown and the main conclusions presented, especially regarding their contribution to consolidate the triggering of magnet mass production. The status of respective manufacturing stages in EU and in JA are also evoked.

Manufacture of the Winding Pack and Development of Key Parts for the JT-60SA Poloidal Field Coils

In order to fabricate the central solenoid (CS) and equilibrium field (EF) coil conductors for JT-60 Super Advanced (JT-60SA), the jacketing facility of 680 m was constructed at Naka site of Japan Atomic Energy Agency. The dummy copper conductors of 10 m and superconductors of 7 m were fabricated. The attachment sleeve to connect the cable and winch wire to pull cable through a 551 m jacket in maximum was developed. The sleeve attained the 30 kN of pulling force. In order to investigate the strand damage by the edge of central spiral through compaction and bending process, the measurements of strand critical current in prototype EF conductor with bending curvature radius of 150 mm was conducted. The degradation of was not observed.