Nuclear Fusion

The safe, sustainable, and nearly inexhaustible generation of energy through nuclear fusion is one of the great technological challenges of our time. After the 2021 breakthrough proved that fusion can release more energy than is required to initiate the reaction, the focus is shifts to overcoming the remaining technological hurdles on the path to building fusion power plants. For fusion reactors to contribute to reliable energy supply in the future, novel materials and manufacturing technologies are needed that can withstand extreme thermal, mechanical, and chemical conditions. Fraunhofer IWS is developing key technologies that make a significant contribution to the realization of components for future fusion power plants.

Materials and Manufacturing Technologies for Nuclear Fusion

Our focus is on the development of highly specialized materials and coatings, as well as advanced manufacturing processes, that produce durable and high-performance components capable of withstanding the complex and extreme conditions of fusion reactors. By considering these cross-sectional technologies relevant to power plant construction, we address both magnetic confinement and inertial fusion. In addition, long-term material characterization – a core competence of Fraunhofer IWS – ensures component reliability under realistic operating conditions.

Research Focuses

Highly Specialized Materials and Coatings

Tritium Barrier Layers

Tritium-deuterium mixtures will be important as fuel for the reactors. To minimize the loss of tritium and other hydrogen isotopes in fusion facilities, Fraunhofer IWS is developing innovative tritium barrier layers. Within the TritiumStopp project, high-density ta-C (tetrahedral amorphous carbon) layers are engineered.

Material Design in Connection with Process Technologies

In the ORCHESTER project, we link material design directly with manufacturing technology: During the Additive Manufacturing process, the alloy design is actively adjusted through precisely controlled powder nozzle systems to respond to different application requirements from the material side.

Scalable, Safe Processes

Additive Manufacturing of Large Components and Multi-material Parts

In fusion reactors, extremely high and low temperatures, strong magnetic fields, and high-energy neutron radiation impact the surrounding structure. Additive Manufacturing enables the production of highly integrated components from advanced materials that meet these requirements. For the construction of complex fusion reactor components, we are researching Additive Manufacturing of large components and multi-material systems. The focus is on high-performance materials such as high-entropy alloys (HEA), titanium aluminides, titanium- and nickel-based alloys, as well as copper and its alloys, e.g., CuCrZr.

Material Characterization

To ensure the durability and reliability of components in fusion reactors, we conduct comprehensive material characterization. A key focus is on material fatigue and the assessment of long-term behavior under realistic operating conditions.