Validation of special processes for the integration activities of the JT-60SA TF coils manufactured in Italy

•Insertion.•Casing welding.•Casing embedding. In the framework of the Broader Approach Agreement for the construction of the JT-60SA tokamak, ENEA provides 9 of the 18 toroidal field (TF) coils of the JT-60SA magnet system. The 9 coils are being manufactured by ASG superconductors in Genoa under the supervision of ENEA in collaboration with the JT-60SA European home team. The manufacturing is composed of two main steps: one concerning winding pack assembly and impregnation, and the other devoted to the integration into the casing structure and associated final coil preparation. This paper describes the results of the validation activities set-up for the integration phase. Specifically, welding of casing components has been retained particularly critical for at least three reasons: (i) during welding the WP may be damaged by the intense heating; (ii) distortion caused by heating may determine incorrect coil geometry and then field errors; and (iii) flaws may reduce structural strength and then the overall lifetime of the machine. Similarly, final embedding has been demonstrated on a 1m long mock-up of the coil. Main results and lessons learned are here described.