Combining Chemical Vapor Deposition and Spark Plasma Sintering for the Production of Tungsten Fiber‐Reinforced Tungsten (Hybrid – Wf/W)

Abstract

Successful upscaling of tungsten fiber‐reinforced tungsten composites (Wf/W) on industrial level could represent an important milestone for future nuclear fusion reactors. The primary objective of these materials is to enhance the durability and operational lifespans of critical components. Developing mature manufacturing approaches remains a challenge, highlighting the need for innovative solutions. This study evaluates the feasibility of merging chemical vapor deposition (CVD) with spark plasma sintering (SPS) for producing such composites. This analysis indicates that combining CVD‐W sealed tungsten fabrics with SPS requires additional manufacturing steps or the utilization of tungsten powders for effective sintering. The process is currently only suitable for simple textile structures utilizing single filaments, mitigating one of the main advantages of CVD. Configurations such as radially braided yarns are currently less compatible to the high stress levels during SPS. A key outcome of this work is the introduction of a thin secondary CVD‐W interface into the composite design, substantially improving the stability of the yttria‐interface and effectively shielding the W‐fibers from potential matrix interactions. This innovation reduces issues such as carbon embrittlement and allows the potential integration of tungsten fibers into different matrix materials such as ceramics, broadening the potential application range of tungsten fiber‐reinforcements.