Multi-Scale Analysis And Characterization of The ITER Pre-Compression Rings

The toroidal field (TF) system of ITER Tokamak composed of 18 "D" shaped Toroidal Field (TF) coils during an operating scenario experiences out-of-plane forces caused by the interaction between the 68kA operating TF current and the poloidal magnetic fields. In order to keep the induced static and cyclic stress range in the intercoil shear keys between coils cases within the ITER allowable limits [1], centripetal preload is introduced by means of S2 fiber-glass/epoxy composite pre-compression rings (PCRs). Those PCRs consist in two sets of three rings, each 5 m in diameter and 337 x 288 mm in cross-section, and are installed at the top and bottom regions to apply a total resultant preload of 70 MN per TF coil equivalent to about 400 MPa hoop stress. Recent developments of composites in the aerospace industry have accelerated the use of advanced composites as primary structural materials. The PCRs represent one of the most challenging composite applications of large dimensions and highly stressed structures operating at 4 K over a long term life. Efficient design of those pre-compression composite structures requires a detailed understanding of both the failure behavior of the structure and the fracture behavior of the material. Due to the inherent difficulties to carry out real scale testing campaign, there is a need to develop simulation tools to predict the multiple complex failure mechanisms in pre-compression rings. A framework contract was placed by ITER Organization with SENER Ingenieria y Sistemas SA to develop multi-scale models representative of the composite structure of the Pre-compression rings based on experimental material data. The predictive modeling based on ABAQUS FEM provides the opportunity both to understand better how PCR composites behave in operating conditions and to support the development of materials by the supplier with enhanced performance to withstand the machine design lifetime of 30,000 cycles. The multi-scale stress analysis has revealed a complete picture of the stress levels within the fiber and the matrix regarding the static and fatigue performance of the rings structure including the presence of a delamination defect of critical size. The analysis results of the composite material demonstrate that the rings performance objectives under all loading and strength conditions are met.