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Mechanical Resilience

Vibration testing of mechanical resilience of bolometer sensors and sensor holders under ITER-relevant conditions


The ITER bolometer diagnostic will provide the measurement of the total radiation emitted from the plasma, a part of the overall energy balance. Up to 550 sensor channels will be installed in ITER in 71 cameras of various sizes and types. The sensor holder is the component inside those cameras to provide attachment and signal connections to the sensor itself. A design of a sensor holder has been proposed previously based on ceramic front and back plates with wire bonded contacts to the sensor and welded signal cables.

This concept can provide the reliable electrical connections required for ITER at temperatures up to 350 C and had been prototyped and proven to be manufacturable. In order to verify its resilience against mechanical loads as well as that of the sensors, sensor holder assemblies have been subjected to accelerations on a shaking table. The magnitude of the accelerations applied (in the frequency range from 5 Hz up to 1 kHz) have been deduced based on load definitions from ITER describing the floor response spectra for typical seismic events as well as the ones expected during disruptions due to electro-magnetically induced forces in bolometer cameras and port structures within which they are mounted.

A particular focus has been placed on testing whether it is beneficial to cover the bond wires with a ceramic paste to protect them against fatigue breaks due to vibrations. The tests demonstrated that the chosen sensor assembly is well capable of withstanding all applied loads without failures and thus demonstrating its structural integrity during the expected operations. Within the limited number of load cycles no need to apply the ceramic paste could be identified.

The ITER bolometer diagnostic shall provide the measurement of the total radiation emitted from the plasma, a part of the overall energy balance. Up to 550 sensor channels will be installed in ITER in up to 71 cameras of various sizes and types. The sensor holder is the component inside all those cameras that provides attachment and signal connections to the sensor itself. It might vary in shape within each camera, but concepts for implementing signal connections and handling of loads in all cameras are very similar, if not identical.

A design of a sensor holder has been proposed previously based on ceramic front and back plates with wire bonded contacts to the sensor and welded signal cables. This concept can provide the reliable electrical connections required for ITER at temperatures up to 350 C and had been prototyped and proven to be manufacturable. In order to verify the resilience of this design as well as that of prototype sensors against mechanical loads, a set of sensor holder assemblies have been manufactured and subjected to accelerations on a shaking table. The previous results from identified a high risk of breaking bond wires during thermal cycling in case a ceramic paste is applied to protect them against vibrations. Accordingly, a particular focus was placed in the current tests to compare the behaviour under mechanical loads with and without ceramic paste.

mechanical resilience, material strength, stress resistance, fracture toughness, fatigue resistance, elastic modulus, impact strength, load bearing capacity, ductility, hardness, durability, tensile strength, compressive strength, shear strength, toughness, plastic deformation, structural integrity, resilience engineering, high performance materials, advanced composites

#MechanicalResilience, #MaterialStrength, #StressResistance, #FractureToughness, #FatigueResistance, #ElasticModulus, #ImpactStrength, #LoadBearingCapacity, #Ductility, #Hardness, #Durability, #TensileStrength, #CompressiveStrength, #ShearStrength, #Toughness, #PlasticDeformation, #StructuralIntegrity, #ResilienceEngineering, #HighPerformanceMaterials, #AdvancedComposites

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