Joining and cycling performance of ultra-thick tungsten coatings on patterned steel substrates for fusion armour applications

Tungsten is the leading candidate to provide a critical protective coating for copper and steel-based plasma facing components in nuclear reactors. However, fabrication of thick tungsten coatings on copper or steel is challenged by the significant difference in the melting points and the thermal exp...

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Autores principales:	Wen Cui, Kieran Flinders, David Hancock, Patrick S. Grant
Formato:	article
Lenguaje:	EN
Publicado:	Elsevier 2021
Materias:	Tungsten Joining Field assisted sintering Dense vertical cracks Spark plasma sintering Strain relief Materials of engineering and construction. Mechanics of materials TA401-492
Acceso en línea:	https://doaj.org/article/6ee5a48a926545628f7724d291c644af
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spelling	oai:doaj.org-article:6ee5a48a926545628f7724d291c644af2021-11-20T04:55:45ZJoining and cycling performance of ultra-thick tungsten coatings on patterned steel substrates for fusion armour applications0264-127510.1016/j.matdes.2021.110250https://doaj.org/article/6ee5a48a926545628f7724d291c644af2021-12-01T00:00:00Zhttp://www.sciencedirect.com/science/article/pii/S0264127521008054https://doaj.org/toc/0264-1275Tungsten is the leading candidate to provide a critical protective coating for copper and steel-based plasma facing components in nuclear reactors. However, fabrication of thick tungsten coatings on copper or steel is challenged by the significant difference in the melting points and the thermal expansion coefficients of the materials, which leads to severe thermal expansion mismatch strains during manufacture and in service. This challenge is investigated using a new processing approach — field assisted sintering of tungsten nanopowders directly onto pre-sculptured steel component surfaces to induce controlled, vertical segmentation cracks that provide strain relief. Tungsten coatings up to 2 mm thick were fabricated with uniform density and with a microstructure consisting of ultrafine grains of ∼200 nm. The coatings showed outstanding thermal cycling durability and survived for at least 50 cycles under pulsed temperature cycles between 300 to 800 °C. Microscopy and in situ thermal imaging revealed that a previously unachievable thermal expansion mismatch strain tolerance was provided by a combination of enhanced tungsten coating adhesion and deliberate coating segmentation by vertical cracking. The approach should be readily adaptable to other dissimilar materials systems to facilitate a range of durable, ultra-thick low ductility coatings on metallic substrates.Wen CuiKieran FlindersDavid HancockPatrick S. GrantElsevierarticleTungstenJoiningField assisted sinteringDense vertical cracksSpark plasma sinteringStrain reliefMaterials of engineering and construction. Mechanics of materialsTA401-492ENMaterials & Design, Vol 212, Iss , Pp 110250- (2021)
institution	DOAJ
collection	DOAJ
language	EN
topic	Tungsten Joining Field assisted sintering Dense vertical cracks Spark plasma sintering Strain relief Materials of engineering and construction. Mechanics of materials TA401-492
spellingShingle	Tungsten Joining Field assisted sintering Dense vertical cracks Spark plasma sintering Strain relief Materials of engineering and construction. Mechanics of materials TA401-492 Wen Cui Kieran Flinders David Hancock Patrick S. Grant Joining and cycling performance of ultra-thick tungsten coatings on patterned steel substrates for fusion armour applications
description	Tungsten is the leading candidate to provide a critical protective coating for copper and steel-based plasma facing components in nuclear reactors. However, fabrication of thick tungsten coatings on copper or steel is challenged by the significant difference in the melting points and the thermal expansion coefficients of the materials, which leads to severe thermal expansion mismatch strains during manufacture and in service. This challenge is investigated using a new processing approach — field assisted sintering of tungsten nanopowders directly onto pre-sculptured steel component surfaces to induce controlled, vertical segmentation cracks that provide strain relief. Tungsten coatings up to 2 mm thick were fabricated with uniform density and with a microstructure consisting of ultrafine grains of ∼200 nm. The coatings showed outstanding thermal cycling durability and survived for at least 50 cycles under pulsed temperature cycles between 300 to 800 °C. Microscopy and in situ thermal imaging revealed that a previously unachievable thermal expansion mismatch strain tolerance was provided by a combination of enhanced tungsten coating adhesion and deliberate coating segmentation by vertical cracking. The approach should be readily adaptable to other dissimilar materials systems to facilitate a range of durable, ultra-thick low ductility coatings on metallic substrates.
format	article
author	Wen Cui Kieran Flinders David Hancock Patrick S. Grant
author_facet	Wen Cui Kieran Flinders David Hancock Patrick S. Grant
author_sort	Wen Cui
title	Joining and cycling performance of ultra-thick tungsten coatings on patterned steel substrates for fusion armour applications
title_short	Joining and cycling performance of ultra-thick tungsten coatings on patterned steel substrates for fusion armour applications
title_full	Joining and cycling performance of ultra-thick tungsten coatings on patterned steel substrates for fusion armour applications
title_fullStr	Joining and cycling performance of ultra-thick tungsten coatings on patterned steel substrates for fusion armour applications
title_full_unstemmed	Joining and cycling performance of ultra-thick tungsten coatings on patterned steel substrates for fusion armour applications
title_sort	joining and cycling performance of ultra-thick tungsten coatings on patterned steel substrates for fusion armour applications
publisher	Elsevier
publishDate	2021
url	https://doaj.org/article/6ee5a48a926545628f7724d291c644af
work_keys_str_mv	AT wencui joiningandcyclingperformanceofultrathicktungstencoatingsonpatternedsteelsubstratesforfusionarmourapplications AT kieranflinders joiningandcyclingperformanceofultrathicktungstencoatingsonpatternedsteelsubstratesforfusionarmourapplications AT davidhancock joiningandcyclingperformanceofultrathicktungstencoatingsonpatternedsteelsubstratesforfusionarmourapplications AT patricksgrant joiningandcyclingperformanceofultrathicktungstencoatingsonpatternedsteelsubstratesforfusionarmourapplications
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Joining and cycling performance of ultra-thick tungsten coatings on patterned steel substrates for fusion armour applications

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