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Tungsten is foreseen presently as the plasma-facing material for divertors in fusion power plants. In order to achieve durable operation of divertors of current fusion reactors, an efficient way of maintaining the divertor functionality is needed. A system capable of in situ tungsten coating of the divertor via low-pressure plasma spraying was proposed to maintain the divertor integrity. In this work, tungsten was deposited on NB31 carbon fibre composite substrates using the low-pressure plasma spraying technology to evaluate the feasibility of this technique. The thickness, porosity, composition, adhesion, and microstructure of the coatings were investigated by scanning electron microscopy image analysis and energy dispersive spectroscopy. Based on the initial results, the spray parameters were iteratively improved in a campaign-based study. The coatings exhibited improving properties through an adjusting of the carrier gas flow, the scanning speed, and the spray distance. By lowering the carrier gas flow, the porosity of the coatings was reduced, resulting in coatings of 98% bulk density. Adjusting the carrier gas flow reduced the amount of semi-molten particles in the coatings significantly. A decrease in both scanning speed and spray distance increased the substrate’s temperature, which led to better adhesion and porosity.

During the spark plasma sintering (SPS) consolidation process, the pressure affects the densification and microstructure evolution of the sintered body. In this paper, the W-Cr-Y-Zr alloy powder was heated to 1000 °C under different applied pressure conditions using spark plasma sintering process, and the effect of pressure on the densification process and microstructure was analyzed. Due to the low sintering temperature, the crystalline size of all the produced W-Cr-Y-Zr alloy is less than 10 nm, which is close to that of the original powders. Cr-rich phase can be detected in the sintered samples due to spinodal decomposition. It is found in this work that the external pressure will increase the contact area between the powder particles, resulting in a higher local pressure at the particle contact, which promotes densification by sliding between the particles under the condition of softening of the particle surface. Additionally, according to the viscous flow theory, the viscous flow activation energy decreases with the increase of pressure. This is because the pressure provides additional driving force to the powder viscous flow process and accelerates the powder shrinkage.

The self-passivating yttrium-containing WCr alloy has been developed and researched as a potential plasma-facing armour material for fusion power plants. This study explores the use of yttria (Y2O3) powders instead of yttrium elemental powders in the mechanical alloying process to assess their applicability for this material. Fabricated through field-assisted sintering, WCr-Y2O3 ingots show Y2O3 and Cr-containing oxides (Cr-O and Y-Cr-O) dispersed at grain boundaries (GBs), while WCrY ingots contain Y-O particles at grain boundaries, both resulting from unavoidable oxidation during fabrication. WCr-Y2O3 demonstrates higher flexural strength than WCrY across all temperature ranges, ranging from 850 to 1050 MPa, but lower fracture toughness, between 3 and 4 MPa·√m. Enhanced oxidation resistance is observed in WCr-Y2O3, with lower mass gain as compared to WCrY during the 20-hour oxidation test. This study confirms the effectiveness of both yttria and yttrium in the reactive element effect (REE) for the passivation of WCr alloy, suggesting the potential of Y2O3-doped WCr for first wall applications in a fusion power plant.

W-Cr-Y smart alloys are potential material candidates for plasma facing components due to their protective behaviour during the loss-of-coolant accident (LOCA), while maintaining beneficial properties of W during the normal operation of the fusion power plant. During plasma exposure, the lighter alloying elements are preferentially sputtered at the surface, but in case of a LOCA, the plasma quenches and sputtering stops and diffusion of the alloying elements to the surface becomes intensive. The diffusion of Cr to the surface due to alloying elements (Y, Ti) yields a protective oxide layer stopping the sublimation of WO3. The phase stability and short-range ordering of ternary alloys in W-Cr-Y(Ti) systems has been investigated, using combination of Density Functional Theory (DFT) and Cluster Expansion (CE) methods with Monte-Carlo (MC) simulations. It has been found out from the DFT calculations, that all pairs in the W-Cr-Y system have positive values of the enthalpy of mixing, while most of the Cr-Ti and Ti-W binary structures have negative enthalpies of mixing. The shift in the short-range order as a function of temperature between Cr and W has been predicted as a result of Y addition in W-Cr-Y alloys compared to W70Cr30, by around 400 K towards lower temperatures. A strong tendency towards clustering of Y has been observed even at elevated temperatures (1800 K). The decrease of the order–disorder transition temperature (ODTT) as a result of the Y addition has been observed, while the addition of Ti has not shown any significant changes in the ordering of W-Cr-Ti alloys compared to W-Cr alloy. Our MC simulations showed that for the W70Cr29Y1 alloy the enthalpy of mixing (Hmix) value is positive in the whole analysed temperature range. Free energy of mixing above 1000 K has been calculated from the first nearest neighbours approximation for W70Cr29Y1 and W70Cr29Ti1 alloys. The results of the present investigations provide an insight enabling for optimizing chemical composition of materials for future plasma facing components.

The tungsten (W) foil laminate is an advanced material concept developed as a solution for the low temperature brittleness of W. However, the deformed W foils inevitably undergo microstructure deterioration (crystallization) during the joining process at a high temperature. In this work, joining of the W foil laminate was carried out in a field-assisted sintering technology (FAST) apparatus. The joining temperature was optimized by varying the temperature from 600 to 1400 °C. The critical current for mitigating the microstructure deterioration of the deformed W foil was evaluated by changing the sample size. It is found that the optimal joining temperature is 1200 °C and the critical current density is below 418 A/cm2. According to an optimized FAST joining process, the W foil laminate with a low microstructure deterioration and good interfacial bonding can be obtained. After analyzing these current profiles, it was evident that the high current density (sharp peak current) is the reason for the significant microstructure deterioration. An effective approach of using an artificial operation mode was proposed to avoid the sharp peak current. This study provides the fundamental knowledge of FAST principal parameters for producing advanced materials.

Tungsten (W) is currently deemed the main candidate for the plasma-facing armor material of the first wall of future fusion reactors, such as DEMO. Advantages of W include a high melting point, high thermal conductivity, low tritium retention, and low erosion yield. However, was an accident to occur, air ingress into the vacuum vessel could occur and the temperature of the first wall could reach 1200K to 1450K due to nuclear decay heat. In the absence of cooling, the temperature remains in that range for several weeks. At these temperatures, the radioactive tungsten oxidizes and then volatilizes. Smart W alloys are therefore being developed. Smart alloys are supposed to preserve properties of W during plasma operation while suppressing tungsten oxide formation in case of an accident. This study focuses on investigations of thin film smart alloys produced by magnetron sputtering. These alloys provide an idealistic system with a homogeneous distribution of the elements W, chromium (Cr), and yttrium (Y) on an atomic scale. The recommended composition is W with 12 weight % of Cr and 0.5 weight % of Y. Passivation and a suppression of WO3 sublimation is shown. For the first time, the mechanisms yielding the improved oxidation resistance are analyzed in detail. A protective Cr2O3 layer forms at the surface. The different stages of the oxidation processes up to the failure of the protective function are analyzed for the first time. Using 18O as a tracer, it is shown for the first time that the oxide growth occurs at the surface of the protective oxide. The Cr is continuously replenished from the bulk of the sample, including the Cr-rich phase which forms during exposure at 1273K. A homogenous distribution of yttria within the W-matrix, which is preserved during oxidation, is a peculiarity of the analyzed alloy. Further, an Y-enriched nucleation site is found at the interface between metal and oxide. This nucleation sites are deemed to be crucial for the improved oxidation resistance.

Self-passivating Metal Alloys with Reduced Thermo-oxidation (SMART) are under development for the primary application as plasma-facing materials for the first wall in a fusion DEMOnstration power plant (DEMO). SMART materials must combine suppressed oxidation in case of an accident and an acceptable plasma performance during the regular operation of the future power plant. Modern SMART materials contain chromium as a passivating element, yttrium as an active element and a tungsten base matrix. An overview of the research and development program on SMART materials is presented and all major areas of the structured R&D are explained. Attaining desired performance under accident and regular plasma conditions are vital elements of an R&D program addressing the viability of the entire concept. An impressive more than 104-fold suppression of oxidation, accompanied with more than 40-fold suppression of sublimation of tungsten oxide, was attained during an experimentally reproduced accident event with a duration of 10 days. The sputtering resistance under DEMO-relevant plasma conditions of SMART materials and pure tungsten was identical for conditions corresponding to nearly 20 days of continuous DEMO operation. Fundamental understanding of physics processes undergone in the SMART material is gained via fundamental studies comprising dedicated modeling and experiments. The important role of yttrium, stabilizing the SMART alloy microstructure and improving self-passivating behavior, is under investigation. Activities toward industrial up-scale have begun, comprising the first mechanical alloying with an industrial partner and the sintering of a bulk SMART alloy sample with dimensions of 100 mm × 100 mm × 7 mm using an industrial facility. These achievements open the way to further expansion of the SMART technology toward its application in fusion and potentially in other renewable energy sources such as concentrated solar power stations.

Tungsten-chromium-yttrium (WCrY) smart alloys are foreseen as the first wall material for future fusion devices such as Demonstration Power Plant (DEMO). While suppressing W oxidation during accidental conditions, they should behave like pure W during plasma operation due to preferential sputtering of the lighter alloying elements Cr, Y, and W enrichment of the surface. In this paper, the erosion performance of WCrY and W samples simultaneously exposed to deuterium (D) plasma with the addition of 1% of the projectile ions being argon (Ar) ions at an ion energy of 120 eV is compared. With reference to the previous experiments at 120 eV in pure D plasma, the erosion for both WCrY and W is enhanced by a factor of ~ 7. Adding Ar to the D plasma suppresses significant W enrichment previously found for pure D plasma. To investigate the impact of the plasma exposure onto the oxidation performance, plasma-exposed and non-exposed reference samples were oxidised in a dry atmosphere. Results show, on the one hand, that the oxidation suppression of WCrY in comparison to pure W is preserved during the plasma performance. On the other hand, it becomes evident that edge effects imposed by the geometry of the samples used in plasma experiments play a significant role for the oxidation behaviour.

The effect of surface roughness on angular distributions of reflected and physically sputtered particles is investigated by ultra-high vacuum (UHV) ion-surface interaction experiments. For this purpose, a smooth (Ra = 5.9 nm) and a rough (Ra = 20.5 nm) tungsten (W) surface were bombarded with carbon ions 13C+ under incidence angles of 30° and 80°. Reflected and sputtered particles were collected on foils to measure the resulting angular distribution as a function of surface morphology. For the qualitative and quantitative analysis, secondary ion mass spectrometry (SIMS) and nuclear reaction analysis (NRA) were performed. Simulations of ion-surface interactions were carried out with the SDTrimSP (Static Dynamic Transport of Ions in Matter Sputtering) code. For rough surfaces, a special routine was derived and implemented. Experimental as well as calculated results prove a significant impact of surface roughness on the angular distribution of reflected and sputtered particles. It is demonstrated that the effective sticking of C on W is a function of the angle of incidence and surface morphology. It is found that the predominant ion-surface interaction process changes with fluence.

The self-passivating tungsten-based alloy W-11.4Cr-0.6Y (in wt.%) is a potential plasma-facing material for the first wall of future fusion reactors, which has been shown to suppress oxidation of tungsten and withstand temperatures of up to 1000 °C. In this study, the effect of Y addition on the microstructure and oxidation behavior of W-11.4Cr alloy at 1000 °C is analyzed by comparing it with W-11.4Cr-0.6Y, both prepared using identical synthesis routes. While the binary W-Cr alloy already exhibits improved oxidation resistance over pure W due to the formation of an outer Cr2WO6 layer, it still shows a tendency for spallation and, hence, is not protective. A continuous passivating chromia layer is only obtained with the addition of Y, and we demonstrate that it results in a 50-fold decrease in the oxide growth rate and eliminates the preferred growth of the oxide at edges seen in the binary alloy. Although a porous, complex oxide scale containing mixed oxide layers and WO3 is formed in both cases, the addition of Y results in lower porosity, which makes the oxide scale more adherent.