To address the risk of flow non-uniformity in the Water-Cooled Ceramic Breeder (WCCB) blanket of the China Fusion Engineering Test Reactor (CFETR), three acrylic-based test sections were developed for flow visualization experiments: (1) 1:5 scaled outboard segment model featuring hydraulically equivalent pipes regulated by pinch valves, (2) first wall (FW) model with 39 U-shaped cooling channels, and (3) breeding zone (BZ) model comprising four groups of 29 cooling tubes each. A key contribution of this work is the development of the scaling strategy for outboard segment test section based on equal Euler number (Eu) and cooling water velocity matching, resolving scaling conflicts between the high-pressure/high-temperature prototype and the ambient-condition test section. Computational Fluid Dynamics (CFD) optimization showed that the maximum deviation in blanket module between the 1:5 scaled outboard segment, and the full-scale prototype is 6.1%. For FW test section, geometric optimizations—including inlet pipe downsizing and manifold wall thinning—reduced the maximum deviation in channel flow distribution to 0.51%, while the cooling water streamlines in the manifold closely matched those of the prototype. Mass flow rates in the cooling channels are measured using both Doppler-based ultrasonic flowmeters and Particle Image Velocimetry (PIV), enabling cross-validation and detailed characterization of the internal flow field. This test section design provides high-fidelity experimental support for the hydraulic optimization of the CFETR WCCB blanket.
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