ORNL Researchers Achieve 3D Printed Defect-Free Tungsten Components

Researchers at Oak Ridge National Laboratory (ORNL) have successfully utilized additive manufacturing to produce the first defect-free, complex tungsten parts, a significant advancement for applications in extreme environments, particularly in clean-energy technologies like fusion energy.

Advancing Fusion Energy with Tungsten

Tungsten’s extremely high melting point, the highest of any metal, makes it ideal for use in fusion reactors, where plasma temperatures can exceed 180 million degrees Fahrenheit—significantly hotter than the sun’s core at approximately 27 million degrees Fahrenheit. Despite its desirable thermal properties, pure tungsten is notoriously brittle at room temperature and prone to shattering.

Innovative Manufacturing Technique

To overcome tungsten’s brittleness, ORNL researchers developed an electron-beam 3D printer capable of depositing tungsten layer by layer into precise three-dimensional shapes. This innovative technology employs a magnetically directed stream of particles within a high-vacuum enclosure, effectively melting and binding tungsten powder into solid-metal objects. The vacuum environment is crucial as it minimizes contamination from foreign materials and reduces residual stress, which are common issues in traditional manufacturing methods.

Significance of the Invention

“Electron-beam additive manufacturing is promising for the processing of complex tungsten geometries,” said Michael Kirka, a researcher at ORNL. This method represents a substantial step forward in expanding the use of temperature-resistant metals in energy resources, contributing to the development of sustainable, carbon-free future energy solutions.

The ability to 3D print defect-free tungsten components opens new possibilities for the deployment of advanced materials in extreme conditions, enhancing the efficiency and durability of next-generation fusion reactors and other high-temperature applications. This breakthrough underscores the potential of additive manufacturing to revolutionize materials science and energy technology.

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