There are currently 7.6 billion people living on Earth. It is predicted that there will be 11 billion inhabitants by the end of the century. As the world's population increases, so does energy consumption. The research project currently being carried out at the ITER (International Thermonuclear Experimental Reactor) in Cadarache in the south of France is intended to pave the way for mankind to a climate-friendly, efficient and safe source of energy - nuclear fusion. Electron beam technology plays a key role in the experiment.

Thirty-five nations are working on the mega project, including European countries, Russia, the USA and China. The magnetic fusion device is intended to prove the feasibility of fusion as a large-scale and carbon-free energy source on our planet and imitate the principle of the sun. The core component of the international experimental power plant is a gigantic donut-shaped reactor. This contains a vacuum vessel weighing around 8,000 tons made of chrome-nickel steel, a special production with a quality specified specifically for ITER. In the future, a strong magnetic field will hold one gram of deuterium-tritium gas on narrow helical paths. This gas will be heated to 150 million degrees Celsius and brought into the plasma state. The plasma is hotter than the sun itself, so its principle of energy output can be simulated.

Electron beam adds tons of weight to boiler

In order to withstand the forces involved, five of the nine sectors of the vessel were welded using Pro-Beam 's electron beam technology. "Never before had electron beam been used in nuclear pressure vessel construction. We therefore had to do a lot of convincing twenty years ago when we presented our technology as the most suitable solution for the planned welding tasks. In addition, even the French nuclear regulations RCC-MR had to be specially adapted to the electron beam," says Dr. Thors-ten Löwer, CTO at the Pro-Beam Group. In 2001, Fusion for Energy integrated the German specialist into the development of the production strategy. The positive characteristics of the technology convinced the decision-makers. In addition, Pro-Beam has the largest civilian welding system in the world and was therefore able to provide the mechanical basis for the components, which are up to twelve meters high and five meters wide.

The welding system had a huge impact on the development of the various sectors. After numerous feasibility studies and trial welds on test parts for various components of the system, the final welding of the boiler was started in 2017.

Gigantic project - enormous challenges

Due to the collaboration with international companies, a strict schedule must be adhered to throughout the entire project. This is because the parts are processed elsewhere before and after welding. The high concentration of energy in the focal point of the electron beam results in a high power density and therefore enables high welding speeds. This speed and the associated high productivity and efficiency are important in order to stay on schedule. In addition, the robust organizational structures implemented in the company support compliance with the deadlines and the high quality standards of the nuclear code.