Multi-physics modeling and Au-Ni/Rh coating assessment for ITER ion cyclotron resonance heating radio-frequency sliding contacts

ITER is a large scale fusion experimental device under construction in Cadarache (France) intended to prove the viability of fusion as an energy source. Ion Cyclotron Resonance Heating (ICRH) system is one of the three heating systems which will supply total heating power of 20 MW (40-55 MHz) up to one hour of operation. Radio-Frequency (RF) contacts are integrated within the antennas for assembly and operation considerations, which will face extremely harsh service conditions, including neutron irradiation, heavy electrical loads (RF current reaches up to 2 kA with a linear current density of 4.8 kA/m) and high thermal loads. Based on the thermal analysis, the contact resistance is expected to be lower than 7 mΩ to keep the maximum temperature on the louvers lower than 250°C. Few weeks of vacuum (~10-5 Pa) baking at 250°C for outgassing is expected before each plasma experimental campaign, under which the RF contact materials' mechanical properties change and diffusion phenomena between different materials are inevitable. CuCrZr and 316L are proper base materials for ITER RF contact louvers and conductors respectively. In order to improve the RF contact's wear and corrosion resistivity as well as to reduce the contact resistance, Au-Ni and Rh functional layers could be electroplated on CuCrZr and 316L accordingly. The application of the Au-Ni/Rh coating pairs is assessed through the thermal ageing and diffusion tests. Wear and electrical contact performances of the Au-Ni/Rh pairs are deeply studied on a dedicated tribometer operated at ITER relevant conditions.