High Speed Copper Machining

Fabrication of high heat flux (10-20 MW/m²) components for the International Thermonuclear Experimental Reactor (see below for more information) required machining of the selected CuNiBe alloy to incorporate complex coolant channels as shown in the attached figure. High speed machining parameters were developed in cooperation with the Boeing's Advanced Materials Fabrication Facility in St. Louis specifically to meet the close tolerance machining needs for thin webs or slots between cooling channels or fins. These webs and slots are 1-1.5 mm wide and 4-6 mm tall or deep. Although some of the detail parameters are proprietary, the spindle speeds were 12,000 to 15,000 rpm with feed rates of 160 ipm.

High Heat Flux, Medium Scale Test Samples

High Energy Systems