1. TIK 3.1 Moderator & Reflector System
TAC Meeting
15. October 2015 | Yannick Beßler (FZJ), Daniel Lyngh (ESS)

2. Outline Juelich ESS M&R System Project Team and Organization
Focus areas of recent weeks
Cold Moderator concept
Thermal Moderator ongoing manufacturing tests
Alternative Reflector concept
Twister concept
Focus areas of the next weeks
26. April 2017

3. Juelich ESS M&R System Project Team and Organization
TIK 3.2 & TIK 3.1
ESS Moderator & Reflector System
Project Coordinator
Yannick Bessler
TIK 3.2
Lead Engineer
Marcel Klaus (TUD)
Designer Cryostat
Christian Henkens
Designer LH2 Loop
Florian Hanusch
Hans Quack (TUD)
50% TIK 3.2
50% TIK 3.3
TIK 3.1
Plug structure and Handling system
FEM Engineer
Ulrich Papst
Designer
Johannes Wolf
Reflectors
Stephan Schönen
Ivan Rykossov
Cold Moderators / Thermal Moderators
Petra Schumacher
Marc Hofmann
CFX Engineer
Jörg Wolters
Additional support from FZJ specialist departments
Senior Advisor
Christoph Haberstroh (TUD)
Michael Butzek
Quality Management
26. April 2017

4. Focus areas of recent weeks
Understanding the PDR documents
Cold Moderator stress analysis and optimization (reduce local stress in order to follow the RCC rules)
Thermal Moderator machining and eBeam welding test
Shaft optimization with regard to streaming, bearing concept, stability, simplification, guiding the pipework, handling
Connection Moderators / Reflectors to Shaft
26. April 2017

5. Moderators
Vessel material Aluminum 6061-T6 (3.2 certificate!) Heat cold Moderators ≈ 21.8 kW Design Pressure 17 bar Temperature K Heat thermal Moderators ≈ kW Design Pressure 5 bar Temperature K
Cold Moderator (LH2)
Cold / thermal neutrons
(Moderators)
Be-Spectral Moderator Cross (H2O)
Vacuum chamber
Pre Moderator (H2O)
Fast neutrons
(Target)
26. April 2017

6. Cold Moderator concept (FEM)
S=55MPa (RCC MRx), for welded, irradiated Aluminum 6061-T6 components
@17 bar design pressure
and K temperature
Deformation
Stress
26. April 2017

7. Cold Moderator concept (Heat Al)
selected from a text file with 13 million lines ...
significantly different heat inputs!
(single analyze for each vessel
necessary)
26. April 2017

8. Cold Moderator concept (Heat H2)
26. April 2017

9. Cold Moderator manufacturing step by step
Al 6061-T6
≈250 x 200 x 40
1 cutting
2 milling the grooves via HSC, fixed by frame structure
26. April 2017

10. Cold Moderator manufacturing step by step
3 milling the undercut (stiffening in the core
reduces deformations due to machining)
4 milling the core structure
26. April 2017

11. Cold Moderator manufacturing step by step
5 milling the undercut in the core structure
(option 1: existing grooves filled with ice and milling
Option 2: EDM self made copper electrode
[noncontact process])
6 drilling of in- and outflow holes
26. April 2017

12. Cold Moderator manufacturing step by step
7 EDM wire eroding for good flow condition
8 milling of the bottom structure
26. April 2017

13. Cold Moderator manufacturing step by step
9 assembly parts (way of manufacturing for
the blue part similar to the first part)
26. April 2017

14. Cold Moderator manufacturing step by step
10 milling of the filler groove
(both parts together)
11 assembly of the filler (green part) and eBeam welding
Filler (AlSi12, 2x1mm) manufactured
by micro focus water cutting R5
26. April 2017

15. Cold Moderator manufacturing step by step
30mm
12 final water cutting to remove
the holding structure
13 welding of the pipe connection
(Al-SS-Invar* friction welding)
*Invar is necessary because of thermal expansion
in the long pipework
26. April 2017

16. Cold Moderator (lower)
4mm
60mm
Lower Moderators is a copy of the upper one with 4mm outer wall thickness (stress too high)
and 3mm cover plates
26. April 2017

17. Ongoing manufacturing tests (6061-T6 welding via eBeam)
“Top plate”
1,5 4
1,6
“Vessel”
Variation a.o. of the beam power to find the
best parameters for AL6061 with AlSi12 filler
26. April 2017

18. Ongoing manufacturing tests 2 (6061-T6 welding via eBeam)
Reduction of through
welding thickness
Groove for filler
(AlSi12)
test welding of double T-structures to contact the fluid guides with cover plates (thermal Moderators)
Through weld test: no side
contact needs to be optimized
26. April 2017

19. Ongoing manufacturing tests 3 (6061-T6 welding via eBeam)
Measurement protocol:
High tolerance via HSC
for eBeam welding!
Thermal Moderator vessel
(pre Moderator)
Thermal Moderator cover, full surface
(pre Moderator) fixed by beeswax
mixture for milling the grooves
Position for the filler groove
-maximum tolerance for the cover
diameter ,05mm
-maximum tolerance for the vessel
diameter ,05mm
26. April 2017

20. Alternative Reflector concept
Rough improvement concept
3 easily cylinders with cooling channels
Channels in series (no risk of clogging)
No housing (problem with cooling)
Easily separation / recycling (save money)
Sealing the discs like SNS target via soft iron sealing
High detail level of the PDR concept therefore
good fallback solution
Concept decision in agreement with Lund end
of October
Be Ø700 x 85
Be Ø700 x 65
Be Ø700 x 50
Alternative Reflector concept1
PDR concept (Be rings with Al walls between the rings)

21. Twister Center of gravity Rotation and lifting device Radial Bearing
Target
Shaft
Step for shielding
Axial Bearing
Moderators & Reflectors
26. April 2017

22. Shaft concept C C Cooling water (>4x750mm²) LH2 pipework
core and axial
bearing cooling
solid shaft
26. April 2017

23. Twister bottom bearing
optimized design
1 top bearing (radial)
1 bottom bearing (axial)
26. April 2017
26. April 2017

24. Twister bottom bearing
Spherical roller bearing
Cage
Polyimide contact
surface (just for
positioning)
Coated membrane plate
Positioning pin
26. April 2017

25. Twister top bearing Cryo quick couplings Fixed bearing part
bubble level
Removable bearing part
Chamber to merging the 4
LH2 vacua (just 1 vent line!)
26. April 2017

26. Focus areas of the next weeks
Preliminary Design optimization planned to be ready in October (change meeting to be convened shortly [Nov.])
Cold Moderator incl. Pipework: machining, eBeam welding, leak test, burst test, X-ray, Invar to Invar weld test, Invar to Stainless Steel weld test
Fluid dynamic analysis for thermal and cold Moderators verification
Structural mechanical analysis for Twister, Moderators, Reflectors
Ordering components with long lead time (LH2 Pumps, Be)
RCC MRx training and understanding how we can use it for cryogenic component / beryllium / ..
26. April 2017