Exploring complex high heat flux geometries for fusion applications enabled by additive manufacturing

The geometrical freedom that additive manufacturing (AM) provides enables realisation of formerly impossible design concepts for high heat flux components aimed at use in a fusion reactor. This paper demonstrates a number of these advantages using a tile-based divertor target with two examples of novel cooling geometry. To showcase the potential benefits of high temperature operation using materials newly available for AM processing, tantalum was used as the structural material. Rather than present optimised designs, these two concepts highlight features enabled by this new technology.

Simple quantitative analysis shows heat transfer improvements of 25% for a multiple small pipe concept compared to single pipe designs. Finite element analysis for both designs, including a tungsten armour, also demonstrates a more uniform temperature distribution, reducing thermal stresses below elastic limits for 5 MWm−2 heat flux cases, even with 600 °C coolant. At 10 MW m−2 yield is exceeded but the expectation is further design optimisation should enhance structural integrity.

Overall, there are modest gains in heat flux handling, lifetime, and thermal efficiency compared to existing concepts, but there are significant improvements in waste reduction and remote handling mass, using typically 80% less material. Moreover, integrated manifolding and careful location of coolant connection is suggested to facilitate repair and replaceability, which should also reduce risk associated with qualifying joints.