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

2. 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

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

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

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

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

7. 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.

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

9. 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.

10. 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.

11. 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

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

13. 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

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

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

16. 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.

17. 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

18. 2nd HIP Evacuation of the canister through dedicated openings
Helium leak tests
Sealing of the openings
HIP cycle 580°C
Step 3 completed

19. 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)

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