Features of plasma sprayed beryllium armor for the ITER first wall

Two water-cooled mockups with CuCrZr heat sinks and plasma sprayed beryllium (PS Be) armor, 5 and 10 mm thick respectively, were fabricated at Los Alamos National Laboratory and thermally cycled at Sandia at 1 and 2 MW/m2. The castellated surface of the CuCrZr mechanically locked the armor. The resulting PS Be morphology controlled cracking during thermal cycling. Post test examinations showed transverse cracks perpendicular to the surface of the armor that would relieve thermal stresses but not degrade heat transfer. The mockups and two others previously produced for the European Fusion Development Agreement had somewhat porous armor, with a thermal conductivity estimated to be about 1/4 that of fully dense beryllium, due to the low (600-650 °C) substrate temperature during deposition specifically requested by EFDA to avoid subsequent heat treating of CuCrZr. Some melting of the armor was expected and observed in the tests.