NSTX 2010 experiments were conducted using a molybdenum Liquid Lithium Divertor (LLD) surface installed on the outer part of the lower divertor. This tested the effectiveness of maintaining the deuterium retention properties of a static liquid lithium surface when refreshed by lithium evaporation as an approximation to a flowing liquid lithium surface. The LLD molybdenum front face has a 45% porosity to provide sufficient wetting to spread 37 g of lithium, and to retain it in the presence of magnetic forces. Lithium Evaporators were used to deposit lithium on the LLD surface. At the beginning of discharges, the LLD lithium surface ranged from solid to liquefied depending on the amount of applied and plasma heating. Noteworthy improvements in plasma performance were obtained similar to those obtained previously with lithiated graphite, e.g., ELM-free, quiescent edge, H-modes. During these experiments with the plasma outer strike point on the LLD, the rate of deuterium retention in the LLD, as indicated by the fueling needed to achieve and maintain stable plasma conditions, was the about the same as that for solid lithium coatings on the graphite prior to the installation of the LLD, i.e., about two times that of no-lithium conditions. The role of lithium impurities in this result is discussed. Following the 2010 experimental campaign, inspection of the LLD found mechanical damage to the plate supports, and other hardware resulting from forces following plasma current disruptions. The LLD was removed, upgraded, and reinstalled. A row of molybdenum tiles was installed inboard of the LLD for 2011 experiments with both inner and outer strike points on lithiated molybdenum to allow investigation of lithium plasma facing issues encountered in the first testing of the LLD. (C) 2011 Elsevier B.V. All rights reserved.

The spherical tokamak (ST) is a leading candidate for a Fusion Nuclear Science Facility (FNSF) due to its compact size and modular configuration. The National Spherical Torus eXperiment (NSTX) is a MA-class ST facility in the US actively developing the physics basis for an ST-based FNSF. In plasma transport research, ST experiments exhibit a strong (nearly inverse) scaling of normalized confinement with collisionality, and if this trend holds at low collisionality, high fusion neutron fluences could be achievable in very compact ST devices. A major motivation for the NSTX Upgrade (NSTX-U) is to span the next factor of 3–6 reduction in collisionality. To achieve this collisionality reduction with equilibrated profiles, NSTX-U will double the toroidal field, plasma current, and NBI heating power and increase the pulse length from 1–1.5 s to 5–8 s. In the area of stability and advanced scenarios, plasmas with higher aspect ratio and elongation, high βN, and broad current profiles approaching those of an ST-based FNSF have been produced in NSTX using active control of the plasma β and advanced resistive wall mode control. High non-inductive current fractions of 70% have been sustained for many current diffusion times, and the more tangential injection of the 2nd NBI of the Upgrade is projected to increase the NBI current drive by up to a factor of 2 and support 100% non-inductive operation. More tangential NBI injection is also projected to provide non-solenoidal current ramp-up as needed for an ST-based FNSF. In boundary physics, NSTX measures an inverse relationship between the scrape-off layer heat-flux width and plasma current that could unfavourably impact next-step devices. Recently, NSTX has successfully demonstrated substantial heat-flux reduction using a snowflake divertor configuration, and this type of divertor is incorporated in the NSTX-U design. The physics and engineering design supporting NSTX Upgrade is described.

Recently, an Edge Localized Mode (ELM) control coil was developed for use on the DIII-D tokamak. The coil design represented a significant challenge due primarily to the requirement for the coil insulation to withstand bakeout temperatures of 400°C for extended periods. This requirement ruled out most common organic insulating systems and necessitated a significant prototyping and development effort, leading to the selection of an advanced high temperature glass/polyimide resin system. The development included developing a heating mechanism that provided the discrete temperature ramp cycles and cure cycles required by this exotic resin. To complicate matters, the resin had a limited shelf life. Additionally the coil was small and rectangular in shape with rather small corner radii. This created a corner buildup that was not previously encountered and made dimensional control difficult. Another unique design requirement was the need to apply a sufficient internal pre-load to the wound and cured coil to insure there will be no relative motion between the coil and the Inconel case due to Lorentz forces from the 4 Tesla toroidal field on the vessel center post. This led to development of very unique leaf springs and a significant research and development effort coupled with an equally arduous finite element analysis effort. A satisfactory prototype was produced. This paper will focus primarily on the manufacturing challenges and discuss the prototyping effort.

The Liquid Lithium Divertor (LLD) on NSTX will be the first test of a fully-toroidal liquid lithium divertor in a high-power magnetic confinement device. It will replace part of the lower outboard divertor between a specified inside and outside radius, and ultimately provide a lithium surface exposed to the plasma with enough depth to absorb a significant particle flux. There are numerous technical challenges involved in the design. The lithium layer must be as thin as possible, and maintained at a temperature between 200 and 400 degrees Celsius to minimize lithium evaporation. This requirement leads to the use of a thick copper substrate, with a thin stainless steel layer bonded to the plasma-facing surface. A porous molybdenum layer is then plasma-sprayed onto the stainless steel, to provide a coating that facilitates full wetting of the surface by the liquid lithium. Other challenges include the design of a robust, vacuum- compatible heating and cooling system for the LLD. Replacement graphite tiles that provided the proper interface between the existing outer divertor and the LLD also had to be designed, as well as accommodation for special LLD diagnostics. This paper describes the mechanical design of the LLD, and presents analyses showing the performance limits of the LLD.

The National Compact Stellarator Experiment (NCSX) was designed to test a compact, quasi-axisymmetric stellarator configuration. Flexibility and accurate realization of its complex 3D geometry were key requirements affecting the design and construction. While the project was terminated before completing construction, there were significant engineering accomplishments in design, fabrication, and assembly. The design of the stellarator core device was completed. All of the modular coils, toroidal field coils, and vacuum vessel sectors were fabricated. Critical assembly steps were demonstrated. Engineering advances were made in the application of CAD modeling, structural analysis, and accurate fabrication of complex-shaped components and sub-assemblies. The engineering accomplishments of the project are summarized.

The National Compact Stellarator Experiment (NCSX) was a collaborative effort between ORNL and PPPL. PPPL provided the assembly techniques with guidance from ORNL to meet design criteria. The individual vacuum vessel segments, modular coils, trim coils, and toroidal field coils components were delivered to the Field Period Assembly (FPA) crew who then would complete the component assemblies and then assemble the final three field period assemblies, each consisting of two sets of three modular coils assembled over a 120 vacuum vessel segment with the trim coils and toroidal field coils providing the outer layer. The requirements for positioning the modular coils were found to be most demanding. The assembly tolerances required for accurate positioning of the field coil windings in order to generate sufficiently accurate magnetic fields strained state of the art techniques in metrology and alignment and required constant monitoring of assembly steps with laser trackers, measurement arms, and photogrammetry. The FPA activities were being performed concurrently while engineering challenges were being resolved. For example, it was determined that high friction electrically isolated shims were needed between the modular coil interface joints and low distortion welding was required in the nose region of those joints. This took months of analysis and development yet the assembly was not significantly impacted because other assembly tasks could be performed in parallel with ongoing assembly tasks as well as tasks such as advance tooling setup preparation for the eventual welding tasks. The crew technicians developed unique, accurate time saving techniques and tooling which provided significant cost and schedule savings. Project management displayed extraordinary foresight and every opportunity to gain advanced knowledge and develop techniques was taken advantage of. Despite many risk concerns, the cost and schedule performance index was maintained nearly 1.0 during the assembly phase until project cancellation.In this paper, the assembly logic, the engineering challenges, solutions to those challenges and some of the unique and clever assembly techniques, will be presented.

Photogrammetry, a state-of-the-art technique of metrology employing digital photographs as the vehicle for measurement, has been investigated in the fusion environment. Benefits of this high tolerance methodology include relatively easy deployment for multiple point measurements and deformation/distortion studies. Depending on the equipment used, photogrammetric systems can reach tolerances of 25 microns (0.001 in) to 100 microns (0.004 in) on a 3-meter object. During the fabrication and assembly of the National Compact Stellarator Experiment (NCSX) the primary measurement systems deployed were CAD coordinate-based computer metrology equipment and supporting algorithms such as both interferometer-aided (IFM) and absolute distance measurement-based (ADM) laser trackers, as well as portable Coordinate Measurement Machine (CMM) arms. Photogrammetry was employed at NCSX as a quick and easy tool to monitor coil distortions incurred during welding operations of the machine assembly process and as a way to reduce assembly downtime for metrology processes.

The National Compact Stellarator Experiment, NCSX, is being constructed at the Princeton Plasma Physics Laboratory (PPPL) in partnership with the Oak Ridge national Laboratory. The goal of NCSX is to provide the understanding necessary to develop an attractive, disruption free, steady state compact stellaratorbased reactor design. This paper describes the recently revised designs of the critical interfaces between the modular coils, the construction solutions developed to meet assembly tolerances, and the recently revised trim coil system that provides the required compensation to correct for the “as built” conditions and to allow flexibility in the disposition of as-built conditions. In May, 2008, the sponsor decided to terminate the NCSX project due to growth in the project’s cost and schedule estimates. However significant technical challenges in design and construction were overcome, greatly reducing the risk in the remaining work to complete the project.

The National Compact Stellarator Experiment (NCSX) was a collaborative effort between ORNL and PPPL. PPPL provided the assembly techniques with guidance from ORNL to meet design criteria. The individual vacuum vessel segments, modular coils, trim coils, and toroidal field coils components were delivered to the Field Period Assembly (FPA) crew who then would complete the component assemblies and then assemble the final three field period assemblies, each consisting of two sets of three modular coils assembled over a 120° vacuum vessel segment with the trim coils and toroidal field coils providing the outer layer. The requirements for positioning the modular coils were found to be most demanding. The assembly tolerances required for accurate positioning of the field coil windings in order to generate sufficiently accurate magnetic fields strained state of the art techniques in metrology and alignment and required constant monitoring of assembly steps with laser trackers, measurement arms, and photogrammetry. The FPA activities were being performed concurrently while engineering challenges were being resolved. For example, it was determined that high friction electrically isolated shims were needed between the modular coil interface joints and low distortion welding was required in the nose region of those joints. This took months of analysis and development yet the assembly was not significantly impacted because other assembly tasks could be performed in parallel with ongoing assembly tasks as well as tasks such as advance tooling setup preparation for the eventual welding tasks. The crew technicians developed unique, accurate time saving techniques and tooling which provided significant cost and schedule savings. Project management displayed extraordinary foresight and every opportunity to gain advanced knowledge and develop techniques was taken advantage of. Despite many risk concerns, the cost and schedule performance index was maintained nearly 1.0 during the assembly phase until project cancellation. In this paper, the assembly logic, the engineering challenges, solutions to those challenges and some of the unique and clever assembly techniques, will be presented. Keywords-field period; assembly; coil joint; metrology; welding

The National Compact Stellarator Experiment (NCSX) is being constructed at the Princeton Plasma Physics Laboratory (PPPL) in partnership with the Oak Ridge National Laboratory (ORNL). Its mission is to develop the physics understanding of the compact stellarator and evaluate its potential for future fusion energy systems. Compact stellarators use 3D plasma shaping to produce a magnetic configuration that can be steady state without current drive or feedback control of instabilities. The NCSX has major radius 1.4 m, aspect ratio 4.4, 3 field periods, and a quasi-axisymmetric magnetic field. It is predicted to be stable and have good magnetic surfaces at beta > 4% and to have tokamak-like confinement properties. The device will provide the plasma configuration flexibility and the heating and diagnostic access needed to test physics predictions. Component production has advanced substantially since the first contracts were placed in 2004. Manufacture of the vacuum vessel was completed in 2006. All eighteen modular coil winding forms have been delivered, and twelve modular coils have been wound and epoxy impregnated. A contract for the (planar) toroidal field coils was placed in 2006 and manufacture is in progress. Assembly activities have begun and will be the project's main focus in the next few years. The engineering challenge of NCSX is to meet the requirements for complex geometries and tight tolerances within the cost and schedule constraints of a construction project. This paper will focus on how the engineering challenges of component production have been resolved, and how the assembly challenges are being met.

The national compact stellarator experiment (NCSX) will have an extensive set of external magnetic diagnostics. These include flux loops on the exterior surface of the vacuum vessel. Data from these sensors will be integrated with other magnetic sensors and used for plasma control and to constrain magnetic equilibrium reconstructions. NCSX is currently under construction at the Princeton Plasma Physics Laboratory (PPPL). The ex-vessel flux loops must be installed during machine construction since they will ultimately be trapped in the space between the vacuum vessel and the modular coil support shell. Detailed designs have been completed, locator templates have been fabricated and approximately one third of the 225 total loops have been installed as of mid February 2007. Modeling was performed by PPPL to determine the optimum size, placement and number of turns. Engineering of the flux loops was challenging as they must be accurately positioned, optimized geometry maintained and they must be robust and reliable in a bake and cryogenic environment for the lifetime of NCSX. Designs for the ex-vessel flux loops that meet these requirements are presented.

The National Compact Stellarator Experiment (NCSX) is being constructed at the Princeton Plasma Physics Laboratory (PPPL) in partnership with the Oak Ridge National Laboratory (ORNL). The stellarator core is designed to produce a compact 3-D plasma that combines stellarator and tokamak physics advantages. The engineering challenges of NCSX stem from its complex geometry. From the project's start in April, 2003 to September, 2004, the fabrication specifications for the project's two long-lead components, the modular coil winding forms and the vacuum vessel, were developed. An industrial manufacturing R&D program refined the processes for their fabrication as well as production cost and schedule estimates. The project passed a series of reviews and established its performance baseline with the Department of Energy. In September 2004, fabrication was approved and contracts for these components were awarded. The suppliers have completed the engineering and tooling preparations and are in production. Meanwhile, the project completed preparations for winding the coils at PPPL by installing a coil manufacturing facility and developing all necessary processes through R&D. The main activities for the next two years will be component manufacture, coil winding, and sub-assembly of the vacuum vessel and coil subsets. Machine sector sub-assembly, machine assembly, and testing will follow, leading to First Plasma in July 2009.

The National Compact Stellarator Experiment (NCSX) is being constructed at the Princeton Plasma Physics Laboratory (PPPL) in conjunction with the Oak Ridge National Laboratory (ORNL). The goal of this experiment is to develop a device which has the steady state properties of a traditional stellarator along with the high performance characteristics of a tokamak. A key element of this device is its highly shaped Inconel 625 vacuum vessel. The vessel is being fabricated by Major Tool and Machine, Inc. (MTM) in three identical 120deg vessel segments, corresponding to the three NCSX field periods, in order to accommodate assembly of the device. This paper describes the manufacturing of the vacuum vessel

Stellarators use 3D plasma and magnetic field shaping to produce a steady-state disruption-free magnetic confinement configuration. Compact stellarators have additional attractive properties-quasi-symmetric magnetic fields and low aspect ratio. The National Compact Stellarator Experiment (NCSX) is being constructed at the Princeton Plasma Physics Laboratory (PPPL) in partnership with the Oak Ridge National Laboratory (ORNL) to test the physics of a high-beta compact stellarator with a low-ripple, tokamak-like magnetic configuration. The engineering challenges of NCSX stem from its complex geometry requirements. These issues are addressed in the construction project through manufacturing R&D and system engineering. As a result, the fabrication of the coil winding forms and vacuum vessel are proceeding in industry without significant technical issues, and preparations for winding the coils at PPPL are in place. Design integration, analysis, and dimensional control are functions provided by system engineering to ensure that the finished product will satisfy the physics requirements, especially accurate realization of the specified coil geometries. After completion of construction in 2009, a research program to test the expected physics benefits will start

A spherical torus (ST) fusion energy development path which is complementary to proposed tokamak burning plasma experiments such as ITER is described. The ST strategy focuses on a compact Component Test Facility (CTF) and higher performance advanced regimes leading to more attractive DEMO and Power Plant scale reactors. To provide the physics basis for the CTF an intermediate step needs to be taken which we refer to as the ''Next Step Spherical Torus'' (NSST) device and examine in some detail herein. NSST is a ''performance extension'' (PE) stage ST with the plasma current of 5-10 MA, R = 1.5 m, and Beta(sub)T less than or equal to 2.7 T with flexible physics capability. The mission of NSST is to: (1) provide a sufficient physics basis for the design of CTF, (2) explore advanced operating scenarios with high bootstrap current fraction/high performance regimes, which can then be utilized by CTF, DEMO, and Power Plants, and (3) contribute to the general plasma/fusion science of high beta toroidal plasmas. The NSST facility is designed to utilize the Tokamak Fusion Test Reactor (or similar) site to minimize the cost and time required for the design and construction.