Development of fabrication technologies for the first wall of the HCCR blanket

•The first wall fabrication technologies of the HCCR blanket using laser beam welding (LBW) and hot isostatic pressure (HIP) bonding were developed.•The LBW conditions and procedures were optimized to remove the backing strip and achieve uniform and continuous back beads.•The partial HIP bonding line caused a slight decrease in the tensile strength, but the impact on the HCCR blanket design would be negligible. The helium-cooled ceramic reflector (HCCR) concept is a primary candidate among demonstration fusion power reactor (DEMO) blanket options in Korea. The HCCR blanket is composed of a first wall (FW), a breeding zone, side cover plates and a back manifold. This study focuses on fabrication technologies for the FW using laser-beam welding (LBW) and hot isostatic pressure (HIP) bonding. Permanent backing strips in the pressure boundaries of the HCCR blanket are not allowed according to regulations related to pressure vessels and nuclear pressure vessels because high-pressure helium gas at 8 MPa is used as the coolant. LBW conditions and procedures for the fabrication of a FW without backing strips were investigated using small mock-ups with an advanced reduced-activation alloy called ARAA, which was developed in Korea. The laser beam power, thickness of the cover plate, and width of the backing strips were considered as parameters. The LBW conditions and procedures were optimized to remove the backing strip and achieve uniform and continuous back beads. After LBW, the fabrication of the FW with small mock-ups was completed by joining the back plate with HIP bonding. The small mock-ups were subject to very high temperatures exceeding 1000°C during the LBW and HIP bonding processes, which led to changes in the microstructures and hardness levels. The microstructures and hardness levels were recovered through post-heat treatments performed after HIP bonding. The microstructures of the HIP bonding interface after the heat treatments were observed. A partial HIP bonding line was confirmed and transverse tensile tests were carried out to investigate the impact of the partial HIP bonding line on the mechanical properties of the HIP bonding interface. The tensile strength of the HIP bonding interface was approx. 2% lower than that of the base metal, indicating that the partial HIP bonding line caused a slight decrease in the tensile strength, but the impact on the HCCR blanket design would be negligible.