Housed in the Physical Sciences Laboratory, the WHAM experiment is a partnership between UW-Madison, Massachusetts Institute of Technology and Commonwealth Fusion Systems. The experimental device is under construction near Madison, Wis., and will serve as a prototype for a future next-generation fusion power plant that UW-Madison spinoff Realta Fusion aims to develop. The researchers plan to use their new material in the Wisconsin HTS Axisymmetric Mirror (WHAM). "Currently, damaged reactor components often need to be removed and replaced with a completely new part, which is costly and time consuming." "Another big benefit of the cold spray method is that it allows us to repair reactor components on site by applying a new coating," Ialovega says. During these experiments, he found that when he heated the material to a higher temperature, it expelled the trapped hydrogen particles without modifying the coatings - a process that essentially regenerates the material so it can be used again. Ialovega conducted experiments on the coated material at facilities at Aix Marseille University in France and Forschungszentrum Jülich GmbH in Germany. The researchers discovered that those tiny boundaries facilitate trapping of hydrogen particles. Upon impact, the particles flatten like pancakes and coat the entire surface, while preserving nanoscale boundaries between the coating particles. It consists of propelling particles of the coating material at supersonic velocities onto a surface. Tantalum is inherently good at absorbing hydrogen - and the researchers suspected that creating a tantalum coating using a cold spray process would boost its hydrogen-trapping abilities even more.Ĭreating a cold sprayed coating is somewhat like using a can of spray paint. That's why the researchers set out to create a new surface for plasma-facing reactor walls that could trap hydrogen particles as they collide with the walls. "These hydrogen neutral particles cause power losses in the plasma, which makes it very challenging to sustain a hot plasma and have an effective small fusion reactor," says Ialovega, who works in the research group of Oliver Schmitz, a professor of nuclear engineering and engineering physics. However, some hydrogen ions may get neutralized and escape from the plasma. In fusion devices, plasma - an ionized hydrogen gas - is heated to extremely high temperatures, and atomic nuclei in the plasma collide and fuse. "The simplicity of the cold spray process makes it very practical for applications," Sridharan says. Over the last decade, Sridharan's research group has introduced cold spray technology to the nuclear energy community by implementing it for multiple applications related to fission reactors. "We discovered that the cold spray tantalum coating absorbs much more hydrogen than bulk tantalum because of the unique microstructure of the coating," says Kumar Sridharan, a professor of nuclear engineering and engineering physics and materials science and engineering. Importantly, they discovered the material is exceptionally good at trapping hydrogen particles, which is beneficial for compact fusion devices. They tested their cold spray tantalum coating in the extreme conditions relevant to a fusion reactor and found that it performed very well. The researchers used a cold spray process to deposit a coating of tantalum, a metal that can withstand high temperatures, on stainless steel. With this research, we are the first to demonstrate the benefits of using cold spray coating technology for fusion applications." "Our technology shows considerable improvements over current approaches. "The fusion community is urgently looking for new manufacturing approaches to economically produce large plasma-facing components in fusion reactors," says Mykola Ialovega, a postdoctoral researcher in nuclear engineering and engineering physics at UW-Madison and lead author on the paper. The advance, detailed in a paper published recently in the journal Physica Scripta, could enable more efficient compact fusion reactors that are easier to repair and maintain.
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