The next step in the Wendelstein stellarator line is the large superconducting device Wendelstein 7-X, currently under construction in Greifswald, Germany. Steady-state operation is an intrinsic feature of stellarators, and one key element of the Wendelstein 7-X mission is to demonstrate steady-state operation under plasma conditions relevant for a fusion power plant. Steady-state operation of a fusion device, on the one hand, requires the implementation of special technologies, giving rise to technical challenges during the design, fabrication and assembly of such a device. On the other hand, also the physics development of steady-state operation at high plasma performance poses a challenge and careful preparation. The electron cyclotron resonance heating system, diagnostics, experiment control and data acquisition are prepared for plasma operation lasting 30 min. This requires many new technological approaches for plasma heating and diagnostics as well as new concepts for experiment control and data acquisition.

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Technical challenges in the construction of the steady-state stellarator Wendelstein 7-X

Wendelstein 7-X (W7-X) represents the continuation of fusion experiments of the stellarator type at the Max-Planck Institute for Plasma Physics (IPP). The aim of W7-X is to demonstrate the suitability for a fusion reactor of this alternative type of magnetically confined plasma experiment. W7-X is being built at Greifswald in the northeast of Germany. The size of device (725 tons, height of 5 m, diameter 16 m) and the superconductive magnet system distinguish W7-X from earlier stellarators at IPP. The paper provides a summary of the status of the main components, the mastering of the technical challenges during component acceptance testing and during machine assembly. Latest results of the assembly work are especially highlighted. The scope of the construction of W7-X was modified and additional acceleration measures were implemented to mitigate risks and delays. Some aspects of these changes are explained in this paper.

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Status of Wendelstein 7-X construction

Assembly of the superconducting stellarator Wendelstein 7-X is well advanced, and commissioning of the device is being prepared. A first draft of the commissioning tasks has been developed and will be discussed in this paper.

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Transition From Construction to Operation Phase of the Wendelstein 7-X Stellarator

https://pure.mpg.de/pubman/item/item_2459073_4/component/file_2565890/Giannella_Fatigue.pdf

Fatigue life assessment in lateral support element of a magnet for nuclear fusion experiment "Wendelstein 7-X"

The fivefold symmetric modular stellarator Wendelstein 7-X (W7-X) is currently under construction in Greifswald, Germany. The superconducting coils of the magnet system are bolted onto a central support ring and interconnected with five so-called lateral support elements (LSEs) per half module. After welding of the LSE hollow boxes to the coil cases, cracks were found in the vicinity of the welds that could potentially limit the allowed number N of electromagnetic (EM) load cycles of the machine. In response to the appearance of first cracks during assembly, the Stress Intensity Factors (SIFs) were calculated and corresponding crack growth rates of theoretical semi-circular cracks of measured sizes in potentially critical position and orientation were predicted using Paris’ law, whose parameters were calibrated in fatigue tests at cryogenic temperature. In this paper the Dual Boundary Element Method (DBEM) is applied in a coupled FEM-DBEM approach to analyze the propagation of multiple cracks with different shapes. For this purpose, the crack path is assessed with the Minimum Strain Energy density criterion and SIFs are calculated by the Jintegral approach. The Finite Element Method (FEM) is adopted to model, using the commercial codes Ansys or Abaqus;, the overall component whereas the submodel analysis, in the volume surrounding the cracked area, is performed by FEM (“FEM-FEM approach”) or alternatively by DBEM (“FEM-DBEM approach”). The “FEM-FEM approach” considers a FEM submodel, that is extracted from the FEM global model; the latter provide the boundary conditions for the submodel. Such approach is affected by some restrictions in the crack propagation phase, whereas, with the “FEM-DBEM approach”, the crack propagation simulation is straightforward. In this case the submodel is created in a DBEM environment with boundary conditions provided by the global FEM analysis; then the crack is introduced and a crack propagation analysis has been performed to evaluate the effects of the crack shape and of the presence of nearby cracks on the allowed number of EM load cycles.

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Coupled FEM-DBEM method to assess crack growth in magnet system of Wendelstein 7-X

The Wendelstein 7-X (W7-X) modular stellarator is in the assembly phase at the Max-Planck-Institut fur Plasmaphysik (IPP) in Greifswald, Germany. The goal of the project is to demonstrate that this type of machine is a viable option for a fusion power-plant. The “pentagonal” magnet system of the machine encompasses 50 non-planar and 20 planar superconducting coils with sophisticated support structure. Structural reliability of components as well as resulting deformations and displacements during various modes of operation have to be considered not only for the magnet system but also throughout the whole cryostat whose main components are the plasma vessel, outer vessel, ports, and thermal insulation. A reliable prediction of the W7-X structural behaviour is only possible by employing complex finite element (FE) simulations with a hierarchical set of FE models. A special strategy has been developed and implemented for the task. The design is basically completed, main parameters are defined, and most of the W7-X components are manufactured. Therefore, the focus in the analysis is being shifted to the creation of parametric FE models which allow performing fast analyses of possible non-conformities, changes in the assembly procedure, and future exploration of operational limits. This paper gives an overview of the implemented analysis strategy, the applied safety margins, and focuses on the most remarkable results.

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Structural analysis of W7-X: Overview

The goal of the Wendelstein 7-X (W7-X) stellarator project is to demonstrate that this type of machine is a viable option for a fusion power-plant. At present the W7-X experiment is in the assembly phase at the Max-Planck-Institut for plasma physics in Greifswald, Germany. The reliable prediction of the structural behavior of the W7-X machine is only possible by employing complex finite element (FE) analyses with a hierarchical set of FE models. A special strategy has been developed for the structural analysis which is under implementation now. This paper gives an overview of the analysis strategy, the applied structural criteria and critical issues, and focuses on the most remarkable results. The main attention is paid to the components that have been changed or optimized recently.

W. Chen

Papers

Structural analysis of W7-X: Overview

Main Results and Critical Issues of W7-X Structural Analysis