FAbrication of Tungsten using HOt isostatic pressing and AM (FATHOM)

Project Story

Challenge

Fusion power is an important step towards the UK’s net zero targets, but developing materials that can withstand harsh fusion conditions remains a key hurdle. Tungsten and its alloys are the material of choice for plasma-facing components. However, conventional powder metallurgy (press and sinter) is limited in its ability to produce complex components that can withstand high temperatures (>1000 K) for long periods (>10⁷ s) within the reactor.

Approach

The AMPLab team, led by Prof. Moataz Attallah, investigated laser-based metal 3D printing and net-shape powder hot isostatic pressing (HIPping) of tungsten. Metamorphic applied its expertise in advanced computational design tools and CFD to exploit the geometric freedom these processes offer.

Solution

The combined manufacturing and design routes made possible high-performance tungsten shield designs that cannot be manufactured conventionally. These designs featured novel thermal management, part consolidation and mass reduction.

Outcome

FATHOM improved on the state of the art for plasma-facing tungsten shields and addressed one of fusion technology’s long standing manufacturing challenges. The project also supported UKAEA’s aim of encouraging innovation in fusion heating and cooling systems, materials and manufacturing.