ITER NHF First Wall Full Scale Prototype manufacturing and testing

• Published in: Fusion engineering and design Vol. 220; p. 115317
• Main Authors: Shuff, Robin, Heikkinen, Samuli, Cicero, Tindaro, Bouvier, Erwan, Bossu, Delphine, Boireau, Bruno, Samaniego, Fernando, Sherlock, Paul, Aspinall, Garreth, Hardaker, Stephen, Bushell, Joe, Jilek, Richard, Edwards, Paul, Banetta, Stefano, Zacchia, Francesco
• Format: Journal Article
• Language: English
• Published: Elsevier B.V 01.11.2025
• Subjects: Full scale prototype; High heat flux testing; Hot isostatic pressing diffusion bonding; ITER first wall; Hot isostatic pressing diffusion bonding; High heat flux testing; ITER first wall; Full scale prototype
• ISSN: 0920-3796
• DOI: 10.1016/j.fusengdes.2025.115317

Three beryllium armoured Full Scale Prototype (FSP) Normal Heat Flux (NHF) ITER First Wall (FW) panels have been manufactured and Factory Acceptance Tested (FAT) followed by performance qualification High Heat Flux Testing (HHFT). Each of the FSPs, based on the same ITER FW variant were manufactured by a distinct industrial supplier grouping: i. Alsymex, ii. a consortium composed of Amentum (Jacobs), Leading and Iberdrola and iii. Framatome. The three FSPs followed a manufacturing sequence consisting of Hot Isostatic Pressing (HIP) cycles consolidating wings, central structural beam and beryllium armour to form a solid diffusion bonded final geometry. FSPs were subject to FAT consisting of hydraulic pressure, 7.15 MPa, hot and cold water flow tests, ultrasonic examination, Hot Helium Leak Test (HHLT), 4 MPa He, at 250 ⁰C, visual and dimensional examination. This was followed by High Heat Flux Testing (HHFT), 7500 cycles at 2 MW/m2 & 1500 cycles at 2.5 MW/m2, carried out at the HELCZA facility at CVRez. The results demonstrate a viable manufacturing design, however non-conformities highlight sensitivity to manufacturing processes.