High heat flux engineering for the upgraded neutral beam injection systems of MAST-U

For the initial phase of MAST-U operation the two existing neutral beam injection systems will be used, but must be substantially upgraded to fulfil expected operational requirements. The major elements are the design, manufacture and installation of a bespoke bending magnet and Residual Ion Dump (RID) system. The MAST-design full energy dump is being replaced with new actively-cooled full, half and third energy dumps, designed to receive 2.4 MW of ion power deflected by an iron-cored electromagnet. The main design challenge is limited space available in the vacuum vessel, requiring ion-deflection calculations to ensure acceptable heat flux distribution on the dump panels. This paper presents engineering and physics analysis of the upgraded MAST beamlines and reports the current status of manufacture.