1. Pacific Northwest National Laboratory U.S. Department of Energy Initial Cost Estimates for Development of DCLL TBM Ferritic Steel Structural Components R.J Kurtz 1, A.F. Rowcliffe 2 and S.J. Zinkle 3 1 Pacific Northwest National Laboratory 2 ORNL Consultant 3 Oak Ridge National Laboratory ITER-TBM Planning and Costing Meeting University of California, Los Angeles December 12 -14, 2005

2. DCLL WBS Definitions - R&D Evaluation and development of NDE techniques and procedures for flaw detection and sizing in TBM plates and joints Rowcliffe, Kurtz Non-destructive examination methods 1.8.1.1.2.5.8 Assess irradiation performance of FM steel/be bonded joints (shared with 1.8.1.1.2.8). Rowcliffe, Kurtz Irradiated properties of FS/Be bonded joints 1.8.1.1.2.5.7 Determine irradiated properties for final qualification of prototypic FM steel joints made by US and international vendors Rowcliffe, Kurtz Effects of irradiation on prototypic joints 1.8.1.1.2.5.6 Conduct irradiation program to define effects of neutron irradiation under TBM conditions on properties of FM steels with emphasis on HIP and welded joints; establish relationships between as-fabricated hardness and microstructural properties and irradiated mechanical behavior. Rowcliffe, Kurtz Irradiated properties database 1.8.1.1.2.5.5 Determine unirradiated properties of weld and HIP joints produced by US or international vendors. Results will be used to assess viability of various fabrication methods and provide performance data for design analysis under 1.8.1.1.3 Rowcliffe, Kurtz Properties of FM steel joints 1.8.1.1.2.5.4 Develop manufacturing technologies through industrial vendors for the assembly of TBM box structures, internal ribs, separators, manifolds and piping connections; develop assembly sequences and post-joining heat treatments Rowcliffe, Kurtz Fabrication technologies for TBM assembly 1.8.1.1.2.5.3 Develop manufacturing technologies through industrial vendors for the fabrication of FM steel internally cooled plate components (first wall,top and bottom plate assemblies, back plates etc.) Rowcliffe, Kurtz Fabrication technologies for internally –cooled plates 1.8.1.1.2.5.2 Recommend materials, define fabrication technologies and interface with vendors on the construction of sub-size mock-ups under 1.8.1.1.2.11 Rowcliffe, Kurtz Fabrication technology for mock-ups 1.8.1.1.2.5.1 This WBS includes R&D tasks to determine, for all TBM mock-ups and prototypes, the selection of FM steel compositions and the appropriate fabrication and joining technologies and to assess the operational limitations for the TBM box structure including the FW, internal ribs and separators, manifolds, and connections to piping. Emphasis will be placed on evaluating on-going fabrication R&D in EU and Japan. This task will also evaluate the performance of FM steel joints produced by US and international vendors and provide the data needed for US design analysis under 1.8.1.1.3 Rowcliffe, Kurtz FM steel fabrication development and materials properties 1.8.1.1.2.5 Description Resp. Persons Title WBS Element

3. DCLL TBM Fabrication Schedule Summary *Prototype may or may not be full scale

4. Pacific Northwest National Laboratory U.S. Department of Energy 1.8.1.1.2.5.1 - Fabrication Technology for Mockups n Objective: Recommend materials, define fabrication technologies and interface with vendors on the construction of sub-size mock-ups under 1.8.1.1.2.11 n Period of Performance: FY06 - FY10 n Assumptions: 1900 h/y (same for all tasks), pragmatic approaches to mockup fabrication (e.g., T91, flat plate geometries, non-prototypic fabrication technologies), material supplied by Task 1.8.1.1.2.11. n Cost Basis: 0.50 FTE/y - Scientist n Total Cost: $0.751 M

5. Pacific Northwest National Laboratory U.S. Department of Energy 1.8.1.1.2.5.2 & 1.8.1.1.2.5.3 - Fabrication Tech. for Internally Cooled Plates and TBM Assembly n Objective: Develop manufacturing technologies through industrial vendors for; 1) the fabrication of FM steel internally cooled plate components, 2) the assembly of TBM box structures, internal ribs, separators, manifolds and piping connections, 3) develop assembly sequences, and 4) post-joining heat treatments. n Period of Performance: FY06 - FY10 (may need to extend to FY11) n Assumptions: Industry is used from the beginning to develop fabrication technology, novel fabrication technologies such investment casting and plasma spray approaches, materials science program support for fabrication development is 1.25 FTE/y - Scientist. n Cost Basis: Recent EU experience for development of fabrication and joining technology ($1 M/y + 3% escalation/y), 50% of cost to procure fabricated shapes for entire Japanese TBM used as the basis for fabrication development. n Total Cost: $7.688 M

6. Pacific Northwest National Laboratory U.S. Department of Energy 1.8.1.1.2.5.4 - Properties of FM Steel Joints n Objective: Determine unirradiated properties of weld and HIP joints produced by US or international vendors. Results will be used to assess viability of various fabrication methods and provide performance data for design analysis under 1.8.1.1.3. n Period of Performance: FY06 - FY10 n Assumptions: Cost to perform microstructural analysis, mechanical testing (tensile, creep, fatigue, creep-fatigue, fracture toughness) on a range of welded/HIPed products, interfacing with ITER structural design codes and development of joint testing methods. n Cost Basis: 0.50 FTE/y - Scientist, 1.0 FTE - Technician, $0.025 M/y for specimen fabrication n Total Cost: $1.996 M

7. Pacific Northwest National Laboratory U.S. Department of Energy 1.8.1.1.2.5.5 - Irradiated Properties Database n Objective: Conduct irradiation program to define effects of neutron irradiation under TBM conditions on properties of FM steels with emphasis on HIP and welded joints; establish relationships between as-fabricated hardness and microstructural properties and irradiated mechanical behavior. n Period of Performance: FY07 - FY08 n Assumptions: Use state-of-the-art rabbit capsules, 6 microstructure/weld variants, tensile and fracture, 2 doses, 2 temperatures, 4 multiplicity. n Cost Basis: Recent US/Japan experiments (FY05 dollars): Design/assembly/specimen fabrication - $0.22 M Disassembly - $0.10 M PIE - $0.20 M 0.5 FTE/y Scientist for 2 y, 1 FTE Technician for 1 y, 0.5 FTE Technician (SEM/TEM) for 1 y. n Total Cost: $1.151 M

8. Pacific Northwest National Laboratory U.S. Department of Energy 1.8.1.1.2.5.6 - Effects of Irradiation on Prototypic Joints n Objective: Determine irradiated properties for final qualification of prototypic FM steel joints made by US and international vendors. n Period of Performance: FY08 - FY10 n Assumptions: Use one temperature controlled RB capsule with 3 sub-capsules at different temperatures n Cost Basis: Recent US/Japan experiments (FY05 dollars): Design/assembly - $0.60 M Surveillance - $0.15 M Specimen fabrication - $0.20 M Disassembly - $0.15 M PIE - $0.45 M 0.5 FTE/y Scientist for 3 y, 1 FTE Technician for 2 y, 0.5 FTE Technician (SEM/TEM) for 1 y. n Total Cost: $2.600 M

9. Pacific Northwest National Laboratory U.S. Department of Energy 1.8.1.1.2.5.7 - Irradiated Properties of FS/Be Bonded Joints n Objective: Assess irradiation performance of FM steel/Be bonded joints (shared with 1.8.1.1.2.8). n Period of Performance: FY07 - FY08 n Assumptions: The cost of this task is assumed to be 50% of Task 1.8.1.1.2.5.5. n Cost Basis: see Task 1.8.1.1.2.5.5 n Total Cost: $0.516 M

10. Pacific Northwest National Laboratory U.S. Department of Energy 1.8.1.1.2.5.8 - Non-Destructive Examination Methods n Objective: Evaluation and development of NDE techniques and procedures for flaw detection and sizing in TBM plates and joints n Period of Performance: FY06 - FY10 n Assumptions: Development of specialized inspection techniques and probes, effort carried out at national labs/universities, industrial participation may be needed for custom probe fabrication, reliability and effectiveness of NDE techniques will be qualified using prototypic flaws. n Cost Basis: 0.5 FTE/y - Scientist, 0.5 FTE/y - Technician, $0.10 M/y to fabricate qualification specimens. n Total Cost: $1.811 M

11. Pacific Northwest National Laboratory U.S. Department of Energy DCLL WBS Definitions - Design Engineering Provide input on materials properties to design analysis tasks, interface with ITER team on MPH activities and development of structural design criteria; provide interface between design and the development of fabrication technologies under 1.8.1.1.2.5 Rowcliffe, Kurtz Fabrication technology for mock- ups 1.8.1.1.3.1.2.1 This WBS includes the administration and R&D for the evaluation and recommendation of fabrication technology, cost estimate and development of structural design code Rowcliffe, Kurtz FM steel fabrication development and materials properties 1.8.1.1.3.1.2 Description Resp. Persons TitleWBS Element

12. Pacific Northwest National Laboratory U.S. Department of Energy 1.8.1.1.3.1.2.1 - Materials Properties and Fabrication Technology n Objective: Provide input on materials properties to design analysis tasks, interface with ITER team on MPH activities and development of structural design criteria; provide interface between design and the development of fabrication technologies under 1.8.1.1.2.5. n Period of Performance: FY06 - FY10 n Assumptions: Largely a consulting activity to the design team but also a key interface with ITER structural team. n Cost Basis: 0.50 FTE/y - Scientist n Total Cost: $0.751 M

13. Pacific Northwest National Laboratory U.S. Department of Energy Total Costs for Ferritic Steel Structural Component Fabrication R&D + Engineering 17.264Total 0.7511.8.1.1.3.1.2.1 1.8111.8.1.1.2.5.8 0.5161.8.1.1.2.5.7 2.6001.8.1.1.2.5.6 1.1511.8.1.1.2.5.5 1.9961.8.1.1.2.5.4 7.6881.8.1.1.2.5.2 & 1.8.1.1.2.5.3 0.751 1.8.1.1.2.5.1 Total Cost, $MTask