Results of ITER Toroidal Field Coil Cover Plate Welding TestNorikiyo KOIZUMI ＊1, † , Kunihiro MATSUI ＊1 , Tatsuya SHIMIZU ＊1 , Hideo NAKAJIMA ＊1Ami IIJIMA ＊2 and Yoshinobu MAKINO ＊2 Synopsis:In ITER Toroidal Field (TF) coils, cover plates (CP) are welded to the teeth of the radial plate (RP) to fix conductors in the grooves of the RP. Though the total length of the welds is approximately 1.5 km and the height and width of the RP are 14 and 9 m, respectively, welding deformation of smaller than 1 mm for local out-of-plane distortion and smaller than several millimeters for in-plane deformation is required. Therefore, laser welding is used for CP welding to reduce welding deformation as much as possible. However, the gap in welding joints is expected to be a maximum of 0.5 mm. Thus, a laser welding technique to enable welding of joints with a gap of 0.5 mm in width has been developed. Applying this technology, a CP welding trial using an RP mock-up was successfully performed. The achieved local flatness, that is, the flatness of the cross-section of the RP mock-up, is 0.6 mm. The analysis using inherent strains, which are derived from the welding test using flat plates, also indicates that better local flatness can be achieved if the initial distortion is zero. In addition, the welding deformation of a full-scale RP is evaluated via analysis using the inherent strain. The analytical results show that in-plane deformation is approximately 5 mm and large out-ofplane deformation, consisting of approximately 5 mm-long wave distortion and a twist of approximately 1.5 mm in the RP crosssection, is generated. It is expected that the required profile can be achieved by determining the original geometry of an RP by simulating deformation during welding. It is also expected that the required local flatness of a DP can be achieved, since out-of-plane deformation can be reduced by increasing the number of RPs turned over during CP welding. A more detailed study is required.

In an ITER toroidal field (TF) coil, tight tolerances of 1 mm in flatness and a few millimeters in profile are required to manufacture a radial plate (RP), although the height and width of the RP are 13 m and 9 m, respectively. In addition, since cover plates (CPs) should be fitted to a groove in the RP with tolerance of 0.5 mm, tight tolerances are also required for the CPs. The authors therefore performed preliminary and full-scale trials to achieve tight tolerances that meet the required RP manufacturing schedule, such as one RP every three weeks. Before the full-scale trials, preliminary trials were performed to optimize machining procedures, welding conditions and assembly procedures for the RP, and the manufacturing processes for the straight and curved CP segments. Based on these preliminary trial results, full-scale RP and CPs were fabricated. The flatness achieved for the RP is 1 mm, except at the top and bottom where gravity support is insufficient. If the gravity support is suitable, it is expected that a flatness of 1 mm is achievable. The profile of the RP was measured to be within the targeted range, better than 2 mm. In addition, most of the CPs fit the corresponding groove of the RP. Although the issue of hot-cracking in the weld still remains, the test results indicate that this problem can be prevented by improving the geometry of the welding joint. Thus, we can conclude that the manufacturing procedures for RP and CP have been demonstrated.