9.4 Advanced Materials Development and Testing

Fusion materials development is a complex process involving identifying requirements, selecting candidates, and optimizing performance. It requires extensive testing in simulated fusion environments to evaluate material behavior under extreme conditions. Advanced facilities and techniques are crucial for this research.

Computational modeling plays a vital role in guiding materials development, from atomistic simulations to continuum-scale predictions. Novel materials like nanostructured composites and advanced coatings offer promising solutions for fusion applications, but require thorough evaluation and comparison with conventional options.

Advanced Materials Development and Testing for Fusion Applications

Process of fusion materials development

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• Materials development process for fusion applications involves
  • Identifying material requirements based on fusion reactor design and operating conditions (high temperature, intense neutron irradiation)
  • Selecting candidate materials with desirable properties (high melting point, low activation)
  • Synthesizing and processing materials to optimize their performance (powder metallurgy, additive manufacturing)
  • Characterizing material properties using various experimental techniques (electron microscopy, X-ray diffraction)
• Materials testing process for fusion applications includes
  • Exposing materials to simulated fusion environments
    1. Conducting high heat flux testing using plasma accelerators or electron beam facilities (EBTF, PFCTF)
    2. Performing irradiation testing using ion beams or neutron sources to simulate radiation damage (DBF, SNS)
  • Evaluating material performance and degradation mechanisms
    • Analyzing microstructure using electron microscopy and spectroscopy techniques (SEM, TEM, EELS)
    • Assessing mechanical properties through tensile testing, fatigue testing, and creep testing
    • Measuring thermal properties to determine heat conductivity and thermal expansion
  • Validating material performance through in-situ testing in fusion devices (tokamaks, stellarators)

Facilities for fusion materials research

• Plasma accelerators and electron beam facilities used for high heat flux testing to simulate thermal loads in fusion reactors (EBTF, PFCTF)
• Ion beam and neutron irradiation facilities used for simulating radiation damage in fusion materials (DBF, SNS)
• Characterization techniques employed
  • Electron microscopy (SEM, TEM) for microstructural analysis
  • X-ray diffraction (XRD) for phase identification and lattice parameter measurements
  • Electron energy loss spectroscopy (EELS) for chemical composition analysis
  • Nanoindentation for local mechanical property measurements
• Mechanical testing equipment utilized
  • Tensile testing machines for strength and ductility measurements
  • Fatigue testing machines for cyclic loading experiments
  • Creep testing machines for evaluating high-temperature deformation

Computational modeling in materials development

• Atomistic simulations guide materials development
  • Molecular dynamics (MD) simulations study defect formation and evolution
  • Density functional theory (DFT) calculations analyze electronic structure and bonding
• Mesoscale simulations predict material behavior
  • Phase-field modeling predicts microstructural evolution under irradiation
  • Dislocation dynamics simulations study plastic deformation mechanisms
• Continuum-scale simulations model component-level performance
  • Finite element analysis (FEA) models thermo-mechanical behavior
  • Computational fluid dynamics (CFD) simulates heat and mass transfer in coolant channels
• Integration of multiscale modeling approaches
  • Linking atomistic, mesoscale, and continuum-scale models provides comprehensive understanding
  • Computational models are validated using experimental data

Novel materials for fusion applications

• Nanostructured materials exhibit enhanced properties
  • Increased strength and radiation resistance due to high density of grain boundaries (nanocrystalline tungsten)
  • Enhanced thermal stability and creep resistance (nano-oxide dispersion strengthened steels)
• Composite materials combine distinct properties
  • Improved fracture toughness and thermal conductivity (SiC/SiC composites, Cu-based metal matrix composites)
• Advanced coating technologies mitigate surface degradation
  • Protective coatings reduce erosion, corrosion, and tritium permeation (tungsten-based coatings, MAX phase coatings)
• Evaluation of novel materials involves
  • Systematic testing and characterization to assess performance under fusion-relevant conditions
  • Comparison with conventional materials to determine advantages and limitations
  • Techno-economic analysis to evaluate feasibility of large-scale production and implementation