Plasma Spraying of a Microwave Absorber Coating for an RF Dummy Load

The European fusion reactor research facility, called International Thermonuclear Experimental Reactor (ITER), is one of the most challenging projects that involves design and testing of hundreds of separately designed reactor elements and peripheric modules. One of the core elements involved in plasma heating are gyrotrons. They are used as a microwave source in electron–cyclotron resonance heating systems (ECRH) for variable injection of RF power into the plasma ring. In this work, the development and application of an alumina-titania 60/40 mixed oxide ceramic absorber coating on a copper cylinder is described. The cylinder is part of a dummy load used in gyrotron testing and its purpose is to absorb microwave radiation generated by gyrotrons during testing phase. The coating is applied by means of atmospheric plasma spraying (APS). The absorber coating is deposited on the inner diameter of a one-meter cylindrical tube. To ensure homogeneous radiation absorption when the incoming microwave beam is repeatedly scattered along the inner tube surface, the coating shows a varying thickness as a function of the tube length. By this it is ensured that the thermal power is distributed homogeneously on the entire inner tube surface. This paper describes a modeling approach of the coating thickness distribution, the manufacturing concept for the internal plasma spray coating and the coating characterization with regard to coating microstructure and microwave absorption characteristics