1. Leslie Jones Target Design Engineer Goran Skoro, Steve Lilley, (Stuart Ansell)– Neutronic Dan Wilcox – Engineering Simulation Dan Coates – CAD - TRaM ISIS TS1 Upgrade Target Design for Manufacture High Power Targetry Workshop 11 th – 15 th April 2016

2. Transition from models/simulations into physical target ISIS Target Manufacturing Facility TS1 Upgrade MK-6B TRAM (baseline model) Target thermo-mechanical model – engineering simulation Design for manufacture – how can we make it Summary Introduction

3. ISIS Target Manufacturing Facility TS1 Target Assembly TS1 Target Plates After HIP TS2 Target Assembly HIP EB Welder NDT Scanner

4. Target Manufacturing Experience Since 2006 ISIS has gradually transitioned from outsourcing 100% manufacture of our targets modules to establishing a dedicated - ‘Target Manufacturing Facility’ – early 2013 >90% processes now in-house. Valuable knowledge and experience from being involved through all stages. Identified weak areas of TS2 Target design – EB weld penetration Implemented changes - service life improved.

5. RECTANGULAR WATER MODERATOR WITH SINGLE POISON LAYER HYDROGEN MODERATOR BACK WATER MODERATOR CYLINDRICAL TANTALUM CLAD TUNGSTEN PLATE FLAT FRONT TARGET SOLID CYLINDRICAL BERYLLIUM REFLECTOR LIQUID HYDROGEN MODERATOR LIQUID METHANE MODERATOR WITH SINGLE POISON FOIL METHANE MODERATOR WATER PRE-MODERATOR TS1 MK-6B TRaM The Target, Reflector and Moderators are all Inter-related. Because of this the manufactured Target needs to closely match the theoretical model.

6. Target Concept for Thermo-mechanical Evaluation CONCEPT TARGET - Dan Wilcox (Covered in detail in separate presentation) Design optimised for max neutronic output within spec for temperature and stress.

7. TS1TS2TS1 UpgradeDesign Limit Peak Temperature (deg C)184249189N/A Peak Heat Flux (MW/m^2)1.982.432.023 Tungsten Stress [ Beam Only] (MPa) 8915798275 Tantalum Stress [Beam Only] (MPa)1149010675 Tungsten Stress [HIP+ Beam] (MPa) 207191165275 Tantalum Stress [HIP+Beam] (MPa)200* 75 Notes: Tantalum will yield at 200MPa TS1 and TS1 upgrade were modelled with MCNPX+CFX+ANSYS, 200µA HIP pre-stress modelled assuming 500°C ‘lock-in’ temperature TS2 was modelled with FLUKA+CFX+ANSYS, 40µA Target Thermo-Mechanical Results Dan Wilcox

8. Target Module 10 W/Ta Plates Tantalum Pressure Vessel Target Concept for Thermo-mechanical Evaluation

9. Avoid sliding contact between tantalum & tantalum!!

10. Design for Manufacture Option 1 - W/Ta only Option 2 - separate Pressure Vessel Common elements to both – Target Plate design Both have their merits - no decision yet Option 1Option 2

11. Individual Target Plate components Design for Manufacture

12. Compare with current TS1 rectangular target plates

13. Design for Manufacture Current TS1 rectangular target plates require 13 EB welds 4 on each face, 2 on each side + thermowell

14. Design for Manufacture

15. 2mm water channel After HIP and QA checks

16. Design for Manufacture Target Stack for Options 1 & 2 constructed in the same way Target plates made individually Interlocked together and EB welded to form solid stack Water cooling channels ‘exposed’ (WEDM or milling)

17. 10 Plates EB welded together to form a solid Target Stack Pair of Tantalum Manifolds Tantalum Flange Tantalum Window Target sub-assemblies Design for Manufacture Option 1

18. Design for Manufacture Manifolds EB welded to target plate stack Flange added next – Option 1

19. Design for Manufacture Finally the Window High cost to fabricate Flange/Manifolds/Window from Ta Difficult to achieve sufficient weld depth – density, melting point Ongoing development work on EB weld penetration (Separate presentation – Arghya Dey) High number of external welds - risk of water leaks? Weld quality issues at late stage could scrap whole target Not without risk Option 1

20. Option 2 Design for Manufacture 10 Plate Target Stack Stainless steel Pressure Vessel Minimises no. of external welds – 2 + comp Separate manufacturing streams – PV via OM Material cost greatly reduced

21. Design for Manufacture Main section cut from solid rod Central tube profile strengthens and stabilises Wire EDM to cut bore and water channels EDM sinking to cut internal slots for each target plate Conventional milling for other features Option 2

22. Target Stack inserted Thermocouple locators (not shown) Flange EB welded to main section Compression fitting welded in place Leak tested Design for Manufacture Option 2

23. Target ready for leak, flow & pressure tests Design for Manufacture Option 2 Window EB welded in place

24. Swaged thermocouples in 9 out of 10 plates Compression fittings used successfully in TS2 Target Manifold Much greater weld penetration achievable with st.st vs tantalum Easier to manufacture – less risk of scrapping target Design for Manufacture Option 2

25. Design for Manufacture Quality Assurance EB weld parameters established using test pieces Representative of joint to be welded Sectioned, polished, etched, measured Eddy Current technique being investigated HIP bond quality determined by Ultrasound Scan Materials testing programme comparing ‘as received’ with EB welded and HIPed materials

26. Target Size Comparison TS2 TS1 UPGRADE TS1

27. Summary Transition from neutronic models/simulations to physical target ISIS Target Manufacturing Facility TS1 Upgrade MK-6B TRAM (baseline) Target thermo-mechanical model Design for manufacture – Options 1 & 2 Stick to proven manufacturing methods – avoid known issues Incorporate best practices learned from existing TS1/2 target designs QA - test at every stage of manufacture + completion

28. Questions?