First Wall Panel - Overview Typical Dimensions and weight 0.9x1.4 m2 to 1x1.7 m2 800 kg to 1400 kg

Overview of Manufacturing Sequence Step 1: 1st HIP SS/CuCrZr Step 2: Solution annealing for CuCrZr mechanical properties recovery Step 3: 2nd HIP SS/CuCrZr/Be Step 4: Finishing

Machining of CuCrZr plates Bending of CuCrZr plate Machining to size Machining of grooves to house pipes Upper plate (PF) Lower plate

Fabrication of SS finger structure Drilling + Bending + Machining to size Machining of water boxes covers Welding of water box covers – He leak test

Fabrication of pipes/waterboxes assembly (1/2) Bending and cutting of SS pipes Machining of waterboxes Inner waterbox - Outer waterbox

Fabrication of pipes/waterboxes assembly (2/2) Welding of 316LN pipes to inner water box Helium leak tests Welding of water box covers

Assembly of one wing segment (1/2) Assembly of previously manufactured parts Welding Φ 10/12 – 11/12 mm pipes inside water box Welding Φ 26mm drilled holes inside water box Helium leak tests Welding of thin covers on the water box.

Assembly of one wing segment (2/2) All fingers groups on the top CuCrZr plate Helium leak tests

Manufacturing of the beam 1st step Machining of the main structure of the beam Typical dimensions 0.7x1 m2 Machining of beam’s covers (including inlet and outlet pipes interfaces). Machining of structural stainless steel plate to close the beam.

Assembly of wings and beam (1/3) Assembly of the wing segments on the canister (not depicted) Positioning of the beam on the wing segments.

Assembly of wings and beam (2/3) Welding of inlet and outlet pipes inside the beam reservoirs + Helium leak tests. Welding of beam’s covers

Assembly of wings and beam (3/3) Positioning of upper plate. Canister and pipes welding

1st HIP Evacuation of the canister through dedicated openings Helium leak tests Sealing of the openings HIP cycle 1040°C Step 1 completed Heat treatment at 980 ºC

Preparation for 2nd HIP (1/4) Decanning Machining of the external surfaces of the beam

Preparation for 2nd HIP (2/4) Machining of access holes (through the inserts) and of pad seats Machining of CuCrZr surface (strict tolerances)

Preparation for 2nd HIP (3/4) Machining of pure copper foils. Machining and surface preparation of beryllium tiles + Surface preparation of copper + Surface preparation of CuCrZr Assembly of copper foils on the CuCrZr surface.

Preparation for 2nd HIP (4/4) Assembly of Be tiles on the copper foils. This operation is repeated until the whole surface of CuCrZr is covered by beryllium. Positioning and welding of the external canister

2nd HIP Evacuation of the canister through dedicated openings Helium leak tests Sealing of the openings HIP cycle 580°C Step 3 completed

Final machining operations (1/2) Machining of the central slot Final machining of access holes “Cut” of the fingers via EDM Final positioning of the pads Connection of bolt housing Central slot (10 mm)

Final machining operations (2/2) Welding of inlet and outlet pipes for water circulation. Decanning He and hydraulic leak tests. Step 4 completed