Plasma Processes, LLC — Department of Energy SBIR Phase II: 16b

Description

In fusion plasmas, ion cyclotron range of frequency (ICRF) and lower hybrid range of frequency (LHRF) power is anticipated to be a primary auxiliary heating and current drive sources in next step tokamak experiments like ITER. From a technological perspective, several challenges remain including electrical breakdown and material compatibility with a nuclear environment. Copper has been the primary material used in present experiments due to its high thermal and electrical conductivity. In a nuclear reactor, copper will be restricted to thin coatings due to material swelling from neutron bombardment and poor mechanical strength at high temperature expected in fusion reactors. Recent experimental results suggest that high magnetic field or pulsed surface heating limits the attainable electric fields. Copper alloys with higher tolerance to surface fatigue have indeed shown improvements. The natural extension is to develop high strength and high melting temperature refractory metal coatings that are more tolerant to surface fatigue and compatible with nuclear environment. Recent testing at the Massachusetts Institute of Technology (MIT) has shown considerable promise for refractory metal coatings. However, improvements in density and conductivity are needed. During Phase I, innovative electrochemical forming (EL-Form) techniques have been developed that enable the deposition of dense, high purity, well-adhered refractory metal coatings on Inconel substrates. Phase I testing has shown the EL-Form coatings are superior to the previous generation of ICRF refractory metal coatings. During Phase II, the refractory metal coating techniques will be optimized and scaled for coating large antenna straps. The optimized techniques will then be used to produce ICRF antennas that will be tested at MITs Plasma Science and Fusion Center (PSFC). The development of dense, well-bonded refractory metal coatings on Inconel substrates will enable the fabrication of ICRF antennas with improved breakdown resistance and performance. In addition, the same techniques used to produce these deposits on Inconel substrates can be used for other applications including aerospace, defense, propulsion, power generation, electrical contact and switch gear, semiconductor, crucibles, heat shields, x-ray targets, wear and corrosion protection coatings.