Innovative, ultra-low cost fabrication methods

Two fabrication processes are being developed that may significantly enhance fusion as a competitive electrical power source. Currently, the capital cost for experimental, developmental, and commercial fusion power cores is too high. Innovative ultralow cost fabrication methods being developed by Boeing and its vendors may significantly lower the cost of normally-conducting toroidal field (TF) coils. Laser or plasma-arc forming is proposed for the large copper centerpost. This process uses a laser or plasma are to “additively machine” the centerpost with all necessary features including integral coolant passages. The 2.7×10⁶ kg aluminum TF return shell can be fabricated using a spray casting process that atomizes and sprays molten aluminum onto a preform structure and around embedded coolant tubes. A scoping cost study indicated the capital cost of the TF centerpost and return shell leg will be reduced by $330 M (greater than an order of magnitude) which will reduce the projected cost of electricity (COE) by approximately 10%