Researchers investigate 3D printing of tungsten parts for extreme conditions in nuclear reactors

Sougata Roy, assistant professor of mechanical engineering at Iowa State University, is working with innovative processes to contribute to the clean energy future. With a $1 million grant from the U.S. Department of Energy, he is researching the use of 3D printing to develop shields and components for nuclear reactors. His focus is on the use of tungsten, a material that is ideal for fusion reactors due to its high temperature resistance and erosion resistance.

“This work in advanced manufacturing, particularly in using additive manufacturing, is about making a difference,” said Roy, an Iowa State University assistant professor of mechanical engineering and a Building a World of Difference Faculty Fellow in Engineering.

As part of the project, titled “Developing a Robust Ecosystem for Additive Manufacturing of Tungsten for Extreme Applications and Management,” Roy is forming what he calls a DREAM TEAM. This includes Yachao Wang, assistant professor at the University of North Dakota, as well as researchers from Ames National Laboratory, Argonne National Laboratory and Oak Ridge National Laboratory. The partnership is part of the EPSCoR program, which aims to strengthen energy-related research capabilities nationwide.

The focus is on tungsten, an ideal material for the inner walls of fusion reactors due to its high temperature resistance and resistance to erosion from neutron radiation. Traditionally, however, processing tungsten is costly and difficult, as the material is hard and brittle. The researchers therefore rely on unconventional methods such as the laser powder bed-controlled direct energy deposition process, in which tungsten powder is processed layer by layer using a laser under oxygen-controlled conditions.

Roy emphasizes that, in addition to the printing process, physics-based modelling and computer-aided simulations play a central role. Machine learning and artificial intelligence will be used to theoretically underpin the experimental results and develop formulations for tungsten alloys that can withstand the extreme conditions in nuclear reactors.

“We’ll start with pure tungsten,” he said. “Eventually we’ll develop new alloys to resolve this cracking challenge. This is a real DREAM-TEAM,” he said, “nothing like this project can be done alone.”

The project combines extensive expertise and state-of-the-art technologies to advance additive manufacturing in the field of nuclear energy and develop sustainable solutions for the future.