Optimization of high heat flux components for DIII-D neutral beam upgrades

Upgrade of the DIII-D neutral beams leads to enhanced heat loads on many components, such as calorimeter, collimator, and pole shields which protect neutral beam magnets. Power increase from 2.6 MW to 3.2 MW per source leads to a normal heat flux loads of up to 55 MW/m² for the calorimeter. The Princeton Plasma Physics Laboratory is responsible for the design and manufacturing of the upgrades of these components. Heat flux distribution on neutral beam components is very uneven and leads to significant thermal stresses. High heat flux density impact requires surface optimization to reduce surface heat flux projection, and avoid localized melting. Several new design features were introduced to accommodate increased heat loads, such as molybdenum inserts for the pole shields, two-dimensional shaping for the calorimeter, and three-dimensional shape optimization and replaceable copper inserts for the collimator. Additionally, all three components include an optimized cooling system design featuring peripheral cooling of copper components. The optimization process included applying analytical relations for the transient temperature distributions on the high heat flux components. These relations were confirmed by previous DIII-D experimental results. To validate the designs, numerical simulations were performed. Results of the design optimization and numerical simulations will be presented.