Design verification of the gyrotron diamond output window for the upgrade of the ECRH system at W7-X

The 10 MW electron cyclotron resonance heating (ECRH) system at the stellarator Wendelstein 7-X (W7-X) currently relies on the successful operation of continuous wave (CW) 1 MW, 140 GHz gyrotrons which have chemical vapor deposition (CVD) diamond output windows cooled by the industrial silicon oil Dow Corning 200(R) 5 cSt. The window features a 1.8 mm thick diamond disk brazed to two copper cuffs with an aperture of 88 mm, which are then integrated in a steel housing. In the context of the upgrade of the ECRH system towards higher microwave power, this gyrotron design has been significantly advanced to fulfill the requirement of 1.5 MW CW operation, still at 140 GHz. A prototype of this new gyrotron is under development at Thales, France. This paper reports the computational fluid dynamics (CFD) conjugated heat transfer and structural analyses of the diamond window performed using the commercial code ANSYS V19.2 to investigate its performance at 1.5 MW operation. Furthermore, sensitivity studies were also carried out with respect to the absorbed power in the disk and the mm-wave beam radius at the window location. These analyses showed that the window design of the existing 1 MW gyrotrons still works quite well at higher power operation, thus verifying the performance of the window. ... mehrEven in the worst case scenario of 1.5 kW absorbed power, the maximum temperature of 215 °C at the disk center can be safely accepted, being below the conservative limit of 250 °C for CVD diamond. In addition, the non-axial symmetric thermal gradients due to the geometry of the cooling channels lead to thermal stresses in the disk and the cuffs. However, they are much lower than the limits. The copper cuffs experience plasticity deformation in the region of the interface with the diamond disk up to a value of about 1.5 mm.