Innovative Design and Material Solutions of Thermal Contact Layers for High Heat Flux Applications in Fusion Devices

One difficulty associated with the design and development of sacrificial plasma facing components that have to handle the high heat and particle fluxes in ITER is achieving the necessary contact conductance between the plasma protection material and the high-conductivity substrate in contact with the coolant. This paper presents a novel bond idea which is proposed as one of the options for the sacrificial energy dump targets located at the bottom of the divertor legs. The bonded joint in this design concept provides thermal and electrical contact between the armour and the cooled sub-structure while promoting remote, in-situ maintenance repair and an easy replaceability of the armour part without disturbing the cooling pipes or rewelding neutron irradiated materials. To provide reliable and demountable adhesion, the bond consists of a metal alloy, treated in the semi-solid phase so that it leads to a fine dispersion of a globular solid phase into a liquid matrix (rheocast process)¹. This thermal bond layer would normally operate in the solid state but could be brought reversibly to the semi-solid state during the armour replacement simply by heating it slightly above its solidus temperature. Material and design options are discussed in this paper. Possible methods of installation and removal are described, and lifetime considerations are addressed. In order to validate this concept within the ITER time-frame, a R&D programme must be rapidly implemented.