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Mechanical Testing of Joints Processed by Electro- Plating Technology for Brazing of Divertor Components

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Mechanical Testing of Joints Processed by Electro- Plating Technology for Brazing of Divertor Components Mechanical testing of joints processed by electro- plating technology for brazing of divertor components Institute for Applied Materials Wolfgang Krauss, Julia Lorenz, Jürgen Konys, Widodo Basuki Motivation Microstructural features of sheared samples Reliable and adapted joining of components is Reactions of filler metal, functional layers and work piece a general challenge in divertor development, Sheared filler independently of design type and cooling W W W - W joints at RT Filler 4.4 kN medium water or gas. Main failure in W-rod High heat flux testing showed that brittle with propagation of crack W into filler phase formation and missing wetting are 100 µm general risks in brazing divertor components. W parts brazed with Ni-Cu Brazing zone Brazing zone Thus, successful brazing needs innovative Joint types for He or water cooled at 1150°C, Ar, 5 min. shows ductile behavior technologies to overcome such lacks. divertor design Electroplating has the feature to generate W – W, W – steel, W - Cu or stainless steel Impact of aging on Eurofer and stainless steel joints layers acting as barriers, active interlayers or with functional / structural behavior Conditions of tested samples as brazing alloys. The operation conditions Aging of joints Brazed at 1150°C, 5 min, Ar in glass tubes imply to select metals from the transition • As joined elements. Electrochemical behavior of the • Aged at 700°C, 215 h elements allows plating for some elements • Aged at 700°C, 1002 h (e.g. Cu, Ni, Fe or Pd) from aqueous electrolytes. Thus, technological relevance in CT analyses of joints industrial processing will be high. The path Joining Joining towards this goal requires development of zone zone electroplating technology, characterization of the joints and mechanical qualification. After shear testing Impact of ageing Electroplating for joining • Microstructure unchanged • Homogenization of filler Shear testing of Eurofer • No defects generated by ageing Shear testing of aged 215 h at 700°C • No brittle phase formation in contact Tools and filler development for adapted joints Eurofer as joined zone filler base material Removal of surface scales and Development of brazing technology depends on several factors as activation for electroplating metallurgical behavior of filler components in correlations to W or steel Shear testing joining parts, melting points and chemical behavior. Appropriate brazing Etching by needs surface cleaning and activation, interlayers for improved filler K3[Fe(CN)6] * KOH Tungsten currentless behavior and adapted processing steps due to the unique properties of Tungsten and Impact of aging tungsten. Eurofer as joined and quality Interlayers for improved wetting Etching by Testing at RT H2SO4 - HCl - H2O 1.3 M Ni(SO3NH2)2 10g, 20ml, 80ml T = 52 °C, pH = 3.5, 50°C, 5 min Ni i = 10 mA/cm² Eurofer currentless D = 12 µm / h Etching by Pd electrolyte W joint ■ Water based electrolyte (AMI DODUCO) Stainless HNO3 -HF -H2O Pd Ultrasonic view of steel Ratio 20/3/77 ■ Organic electrolytes T = 40°C 50°C, 30 s i = 4 - 8 mA/cm2 brazing zone • EMIM-Cl (Ethyl-Methyl-Imidazolium-Cl) currentless pH = 7.5 • PC (Propylencarbonat Electroplating Electroplated parts Brazed samples Evaluation of parameters with interlayers and filler for shear testing E 13 Electrolyte Type of joints E 7 Cu, Pd or Ni Tungsten Eurofer Shear force F [N] Stainless steel ▲ Tungsten Ø 8 mm ● Eurofer Ø 8 mm Brazing zone d = i f(t)i,T,pH Ni + Cu coated Ni coated Brazing Temp.: 1150°C E 11, 215 h, Brazing Time: 1 - 10 min Defects Type: Moving into hot zone Cracking of W-rod X-Ray tomography of tested samples and cracked zone Qualification of joints by electroplating Mechanical behavior vs. testing conditions and temperature W 3 Shear testing of joints Alloy / Shear RT 450°C Aged, 700°C, Aged, 700°C, E 17 force [kN] 215 h 1002 h W joint shear tested at 450°C Tungsten 11.8 3.3 2.7 - The microstructural analyses pointed out, that Stainless steel > 9 bending 5.8 9.1 7.8 interlayers (Ni, Pd) and filler metal (Cu) can be electroplated on tungsten, Eurofer and stainless Eurofer 11.5 5.2 4.2 7.4 W steel in adjustable thickness and well adherent quality. Cross sections of brazing zones showed Ni Sheared brazing zone • Shear strength is similar for all three brazing combinations Crack homogeneous gap filling indicating good thermal Cu Eurofer, 450°C • Softening at elevated test temperature as expected and mechanical bonding. Oxidized after cracking • At 450°C about 40% of strength of RT value are remaining Mapping of Cu Shear testing was chosen as the first mechanical qualification step to qualify the processed joints due to the simplest sample preparation and testing configuration. Conclusions Testing conditions: The performed investigations show that electroplating is an alternative Sample size: Diameter 8 mm Temperature range: RT to 600° processing technology in the fields of the joining and coating of fusion Atmosphere: Air relevant materials and components. During heating: Preloading of 0.03 kN (a) Universal mechanical testing machine Instron 4505 (b) Schematic diagram of the experimental setup Displacement rate: 0.01 mm/s Homogeneous and well-adherent layers were successfully deposited on tungsten, Eurofer and stainless steel by electroplating Typical behavior of samples during shear testing Mechanical testing was performed in the temperature range RT to 600°C At RT Eurofer samples failed at high strength (L ≈ 230 N/mm²) Aging at 700°C showed diffusion in brazing zone but no significant weakening Mechanical strength still present at elevated temperature At 459 °C failure of W-W joints appear as expected in the braze Brazed steel parts by deposited Cu-Ni layers revealed strength behavior comparable to joints fabricated by common technology Tungsten Stainless steel Eurofer Tungsten aged As brazed As brazed As brazed Annealed at 700°C, 215 h Acknowledgment Testing at RT Testing at RT Tested at 450°C Cracking in brazing zone This project has received funding from the European Union’s Horizon 2020 research and Cracking of W-rod Bending of samples Failure in the braze Similar behavior for testing due to high DBTT of W No failure up to < 9 kN by shearing/sliding at elevated temperatures innovation program under grant agreement number 633053. The views and opinions expressed herein do not necessarily reflect those of the European Commission. KIT – University of the State of Baden-Wuerttemberg and National Research Center of the Helmholtz Association.
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