MATEFU Spring School. Mechanical qualification of magnet components April Klaus-Peter Weiss

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1 MATEFU Spring School April 2009 Mechanical qualification of magnet components Klaus-Peter Weiss Forschungszentrum Karlsruhe, Institute for Technical Physics 1 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

2 CryoMaK CryoMaK-Facility (Cryogenic Material Test Karlsruhe) concentrates on the characterization of mechanical and thermal material properties at cryogenic temperatures. ± 25 kn and ± 50 kn machine Tensile, fracture and fatigue tests High frequency alternating load tests RT- 5 K 650 kn compression or tensile Full size test of components Large volume 400mm RT 4.2 K Thermal Expansion Thermal Conductivity RT 4.2 K 2 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

3 ITER Magnet System The cold mass of the magnet system contains structural material and the superconducting cable Gravitational forces due to the mass of the system Thermal forces due to cool down of the coils Lorentz forces due to the magnetization 3 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

4 Structural materials thermal expansion 0 Thermal expansion, µm/m Al LN Invar Incoloy 908 Ti aged CrMn Steel Temperature, K 4 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

5 Typical temperature dependences of thermal conductivity High thermal conductivity caused by electrons phonons Medium thermal conductivity Electrons & phonons exist but are blocked by scattering Low conductivity No electrons & almost no phononic components Th. Conductivity λ [W/Km] Oxygenfree Copper CIC Silver efunda Temperature T [K] Th. Conductivity λ [W/Km] Stainless Steel 316 CIC Invar 36 CIC Temperature T [K] Th. Conductivity λ [W/Km] 0,30 0,25 0,20 0,15 0,10 0,05 Balsa Wood CIC Teflon CIC 0, Temperature T [K] 5 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

6 Lorentz Force in Magnets and Consequences The Force on a conductor in a magnetic field results from F = l B x I (Lorentz-Force). E.g. for the TF coil I = 68 ka; B at the conductor = 11.5 T this results in a radial force per length F = I B = ka T = 782 ka N/(Am)) = N/m. Beside the radial force the conductor is exposed to a hoop stress that stretches the conductor. 6 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

7 ITER Conductor (CSMC and TFMC) Steps towards a cable Filaments (Strands) Separate isolated subcables (Petal) Isolated cable Conductor Steel conduit CSMC-conductor TFMC-conductor Nb 3 Sn conductors in Incoloy / Steel conduit 7 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

8 ITER conductor jacket specifications TF-jacket 18 coils + 1 spare regular DP ~760m side DP ~415m approx m tubes & welds approx specimen from jacket material after 50 welds one proof sample 200 samples PF-jacket 6 PF coils Depending on position 400 m 900 m approx m tubes & welds 4 specimen per lot After 100 welds one proof sample 100 samples Temp. Young s Modulus (GPa) Yield Strength (MPa) Ultimate Tensile Strength (MPa) Elongation at Failure (%) 300 K 190 >173 >483 >35 N/A 4 K 205 >700 >1000 >40 >150 Fracture Toughness, K IC (MPa m 1/2 ) 8 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

9 Structural Material (magnet casing) 2 CASTING (Upper outer Intercoil Structure) FORGING 1 (Upper inner Intercoil Structure) 3 CASTING (Upper intermediate Intercoil Structure) 7 FORGING (Inner Leg) 4 CASTING (Lower intermediate Intercoil Structure) FORGING 6 (Lower inner Intercoil Structure) CASTING 5 (Lower outer Intercoil Structure) Inner plasma vessel 9 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

10 Structural Materials of Magnet System Casing FORGING 1 (Upper inner Intercoil Structure) 7 FORGING (Inner Leg) FORGING 6 (Lower inner Intercoil Structure) CASTING 2 (Upper outer Intercoil Structure) 3 CASTING (Upper intermediate Intercoil Structure) 4 CASTING (Lower intermediate Intercoil Structure) CASTING 5 (Lower outer Intercoil Structure) Modified Type 316LN material in as cast in as forged & as heavy rolled plates 22 Ø 4 Ø 4 K tensile specimens Superconducting cable Structural materials Type 316LN Incoloy 908 superalloy Al 6000 series Stabilizing materials OFHC Copper Insulation materials GFRP / Epoxy Superconducting materials Nb 3 Sn / bronze TF/CS NbTi / PF High Tc option for current lead Full size (51x 51) CS jacket fatigue life test at 4 K Mat: Type 316LN Interfaces/Joints Welds (TIG/EB/LB) Friction welding Solder joints Brazed joints Adhesive cured bonds e. g. PF conductor insert coil transition 316LN/ 316L TIG 316L/Cu friction weld CuCrZr/ Cu brazed joint 3-point bending test of cable Insulation material at 4 K 10 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

11 International Standards for Testing Standards for tensile testing ASTM E 74 for load verification devices. The primary standards are masses of weights accurate to 0.005% of their values. ASTM E 83-85, Standard Practice for Verification and Classification of Extensometers, Vol , ASTM, Philadelphia 1996 ASTM E , Standard Test Method for Young s Modulus, Tangent Modulus, and Chord Modulus, Vol , ASTM, Philadelphia 1996 DIN EN Teil I IEC , Mechanical Properties Measurement Room Temperature Tensile test of Cu/Nb-Ti composite superconductors, IEC 90/63/CDV, IEC 90/63A/CDV, Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

12 Tensile Experiments 12 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

13 Ferritic steel fracture toughness results 13 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

14 Ferritic steel fracture toughness results Material: C = 0.2 %, Si = 0.55 %, Mn = 1.6 %, P = %, S = % T =295 K K IC ~ 269 MPa m J test conducted at 295 K and LEFM test at 77 K T = 77 K K IC ~ 40 MPa m 14 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

15 Consequences of insufficient fracture toughness 15 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

16 Basic Considerations: Machine compliance and Extensometry The load verification devices are certified with ASTM E 74. The primary standards are masses of weights accurate to 0.005% of their values. Strain is measured indirectly by the elongation of the material. For displacement verification the used standard is ASTM E 83 Commercial extensometer We use averaging extensometers 16 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

17 Extensometers and data acquisition Physical world Signal conditioning Signal conditioning A/D converter PC-Board ~18 bit Data Acquisition software Data Evaluation software 17 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

18 Resolving of local strain during tensile test of a Nb 3 Sn Ø 0.8 mm wire at 295 K 250 Stress, MPa Extensometer # 1 50 Extensometer # 2 0 Extensometer # 3 0,0 0,2 0,4 0,6 0,8 Strain, % 15 Stress, MPa 10 5 Extensometer # 1 Extensometer # 2 Extensometer # 3 0 0,000 0,004 0,008 0,012 Strain, % 18 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

19 Full size jacket material tests at 4 K Full size jacket test At 2 Hz and at a peak load of 440 kn (1100 MPa) 19 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

20 JK2 tensile test series 20 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

21 Material data of JK2 steel File & heat Temp. K Young s Modulus GPa Yield Strength MPa UTS MPa Uniform elongation % Total elongation % Reduction of area % JK2-227* * ,4 JK ,3 82,1 JK ,9 77,8 JK ,9 75,2 JK ,7 64,3 JK ,5 57,6 JK ,5 57,9 JK ,6 49,0 JK ,4 41,8 21 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

22 316LN tensile test series 22 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

23 Material data of 316LN steel File & heat T K Young s Modulus GPa Yield Strength MPa UTS MPa Total elongation % Reduction of area % KIND ,3 KIND ,2 KIND ,9 73,7 KIND ,5* 65,5 KIND ,4 66,9 KIND ,8 60,9 KIND ,7 47,4 KIND ,9 43,8 23 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

24 CS Conductor connection CS jacket with 51 x 51 mm 2 Tensile specimens with 2 mm Ø 24 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

25 Stress strain diagram of SS / copper friction joint at 295 K and at 4.2 K 4.2 K 295 K 25 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

26 Concept of fracture mechanics Crack shapes and geometry factors K = Y σ π 2 a Mode I Mode II Mode III Interior crack Y = 1.00 through-thickness surface crack Y = 1.12 half-circular surface crack Y = Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

27 Fracture toughness tests at 4 K Fracture toughness a tool of fracture mechanics for use in design Historical: Griffith, Orowan, NASA researchers, & NPP design Linear elastic fracture mechanics [K-concept], ASTM standard E 399 K = Y σ π 2 a CT specimen, 43 x 45 x 4 27 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

28 Elastic plastic fracture mechanics [ J-concept] ASTM standard E 813 multi specimen method Specimen # 1 Specimen # 2 Specimen # 3 Specimen # 4 Load, kn J-Integral ~ Area 1 J-Integral ~ Area 2 J-Integral ~ Area 3 J-Integral ~ Area 4 Load line displacements, mm Blunting line J-Integral, N/mm Resistance line Critical J ~ J IC Physical crack extension, mm 28 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009 K IC = (E. J IC ) 0.5

29 Elastic plastic fracture mechanics [ J-concept] ASTM standard E 813 single specimen method Material: ITER Valinox Type 316LN T = 7 K J-Test according E 813 Determine slope kn/mm of each unloading 29 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

30 JETT: J Evaluation on Tensile Test A Novel elastic plastic fracture toughness test method has been developed based on a fundamental solution on J Evaluation on Tensile Test proposed by J. R. Rice J. R. Rice et al., Some further results of J Integral analysis and estimates, in: ASTM Special Technical Publications 536, (1973) p. 231 This new test technique was extensively investigated to find a suitable method for fracture toughness determination with small size simple geometry samples. G L 1 ( G G ) 2 = L1 L 2 D G L1 G L2 b D = Round bar diameter b = net section diameter 30 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

31 JETT - Compact Tension Specimen K IC [MPa m] by JETT K IC [MPa m] by E 399 or E FeCo 316LN Plate 316LN Plate, HT 03Cr20Ni16Mn6 Plate 03Cr20Ni16Mn6 Plate,HT Incoloy 908 plate,ht 316LN conduit,ht Incoloy 908 conduit, HT SUS JN1, Plate 316LN Plate, HT Ti-6Al-2.5Sn Al 2219 Ti-6Al-4Zr-2Mo-2Sn Ti Plate, HT Correlation between JETT test results of various materials and valid ASTM tests 31 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

32 Fatigue Crack Growth Rate (FCGR) CT specimen, 43 x 45 x 4 Crack length versus Cycle number precracking Material: 316LN plate 20 mm thick, 316LN-3 Start cycling with K and 30 Hz For each cycles acquisition of compliance Function crack length versus cycles and da/dn crack length, mm 21,0 20,0 19,0 18,0 17,0 16,0 15,0 14,0 13,0 12, Cycle number N 32 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

33 FCGR Results 1.0E E-03 da dn = C 0 K m da/dn, mm/cycle 1.0E E-05 Incoloy B2 base FZK Incoloy MIT, base July 98 Valinox aged, B37 Siderval aged Cefival aged 1.0E K, MPa m 33 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

34 Full size jacket material tests at 4 K Full size jacket test At 2 Hz and at a peak load of 440 kn (1100 MPa) 34 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

35 Full size jacket material tests at 4 K and 300 K 35 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

36 Cold mass material to be qualified Model 1 Insulation material Model 2 CS cross over weld TF LHe inlet tested under cyclic load 36 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

37 QA for W7-X 30 Number of tests Yield strength, MPa Yield strength of cast material measurements of 259 specimens with respect to different heats Young's modulus, GPa Number of tests at 7 K & 4 K LHe 7 K Yield strength, MPa Collected data of 295 specimens SD 50% -SD 37 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

38 Summary For Fusion application, like superconducting magnet systems material tests are necessary to test and verify the properties at low temperatures. Several test methods were introduced together with some results of candidate structural material to be used for ITER. For comparison: W7-X mechanical qualification and QA during manufacture and assembly conduit, case, welds, bolts, insulation ~ 300 standard tests / year adding special full-size tests 38 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

39 Annex Standards for tensile testing ASTM E 74 for load verification devices. The primary standards are masses of weights accurate to 0.005% of their values. ASTM E 83-85, Standard Practice for Verification and Classification of Extensometers, Vol , ASTM, Philadelphia 1996 ASTM E , Standard Test Method for Young s Modulus, Tangent Modulus, and Chord Modulus, Vol , ASTM, Philadelphia 1996 DIN EN Teil I IEC , Mechanical Properties Measurement Room Temperature Tensile test of Cu/Nb-Ti composite superconductors, IEC 90/63/CDV, IEC 90/63A/CDV, Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

40 Annex 40 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

41 Annex 41 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

42 International Standards for Testing Standards for tensile testing ASTM E 74 for load verification devices. The primary standards are masses of weights accurate to 0.005% of their values. ASTM E 83-85, Standard Practice for Verification and Classification of Extensometers, Vol , ASTM, Philadelphia 1996 ASTM E , Standard Test Method for Young s Modulus, Tangent Modulus, and Chord Modulus, Vol , ASTM, Philadelphia 1996 DIN EN Teil I IEC , Mechanical Properties Measurement Room Temperature Tensile test of Cu/Nb-Ti composite superconductors, IEC 90/63/CDV, IEC 90/63A/CDV, Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

43 Consequences of insufficient fracture toughness 43 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

44 Consequences of insufficient fracture toughness G-ALYY was leased from B.O.A.C. to South African Airways. Flight SA201 was on its way from London to Johannesburg. After a fuel stop in Rome the plane took-off, but only 36 minutes later the radio-contact was interrupted in the area of Stromboli. The next morning remains were found in the sea. Since the sea was at this place as deep as 1000 meters, no parts of the aircraft could be inspected. Only four days after the crash the Comet flights were again suspended, one of the reasons being the similarities to the YP crash. G-ALYY had only performed 2704 flight hours. A very intensive flight test program was performed in order to find out the reason of the YY and YP crashes, with no special conclusion. Only after a very long expensive investigations, which included the assembly of the remains of the crashed YP and the underwater stress test of the YU Comet which came from B.O.A.C. Finally the fuselage of YU broke up on a sharp edge of the forward escape-hatch. After that this rupture was repaired the tests were restarted, but only shortly afterwards the fuselage broke up. This time the rupture started at the upper edge of a window and was three meters long. The YP and YY crashes were due to metal fatigue, which took place because of the crystalline changes in the fuselage skin. They were amplified by the high speed and altitude the Comets were operated. The metal fatigue resulted in ruptures of the fuselage, this had as a consequence a terrible decompression at 33Kft, tearing up the plane with all known consequences. 44 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

45 Un-swaged CuCrZr alloy tensile response at 295 K and at 7 K 7 K 298 K 45 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

46 Swaged CuCrZr alloy tensile response at 295 K and at 7 K 46 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

47 Full size jacket material tests at 4 K 47 Klaus-Peter Weiss FZK ITP MATEFU Spring School, April 05-09, 2009

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