1. Advanced Manufacturing: What is this going to do for us in Fusion?
Fusion Energy Systems Studies
Advanced Manufacturing: What is this going to do for us in Fusion?
FESS Group Discussion
FESS Next Study Kickoff Meeting, Feb 26-28, 2019, Germantown, MD

2. Fusion Things to Manufacture (materials and components)
Blanket module or large “banana” structures
First wall part of blanket, 3 sides of a box
Breeding section of blanket
Back section of blanket box
Attachment to structural ring/strong back
Solid breeder material
Manifolds
PFC material/surface structure
Divertor cooling armor, structure, cooling conduits, manifolding
Advanced cooling structures, impingement, heat transfer enhancement, flow control
Tritium permeation windows
Permeable membranes
Catalysts and hydrogen storage
Coatings (integrated) on other components…………..

3. What does AM mean? Why do I need this?
The process used to make something
The ability to mix materials
The speed of manufacture
The material wastage
The spatial scale of variation in an article produced (complexity)
The material that an object can be made from
The number of steps in a manufacturing process
Comparison to “conventional” manufacturing techniques
Something that cannot be made with conventional manufacturing

4. How does engineering design communicate with AM
Material and component:
7 buckets of powder, Fe, Cr, W, V, Ta, Mn, Si, C + a Giant laser  RAFM
Add some Y2O3 and you get advanced RAFM
What did I just make? It sounds like a metal muffin
What are its properties?
I can make precise shapes since I put down the material in some continuous fashion, even very small bits at a time
How do I control material properties in this process vs conventional manufacturing
Conventional manufacturing,
make molten material with constituents,
make plate or other standard form,
“design” manufacturing steps to produce the properties that are desired along with the part shape….
will need to join separate parts to make a full component (weld, braze, bolt, HIP, etc.)

5. How do we formulate the thermo-mechanical problem in order to take advantage of advanced manufacturing?
Conventional
Advanced
Specify materials and their properties
Specify initial geometry
Specify loads
Are stresses within allowables?
Do some thickening or thinning, retry
Specify loads
Establish range of material properties
Establish range of geometries
Solve for properties and geometry distribution to minimize stresses
Does this mean I can no longer use vendor software to do Thermo-Mechanical Design?