Researchers at Oak Ridge National Laboratory (ORNL) have successfully produced the first complex tungsten parts that are free of defects using additive manufacturing, a breakthrough that could significantly benefit clean-energy technologies like fusion energy.
Tungsten, known for its exceptionally high melting point, is perfect for fusion reactors where plasma temperatures soar past 180 million degrees Fahrenheit—remarkably hotter than the sun's core, which is around 27 million degrees Fahrenheit.
In its natural state, tungsten is brittle at room temperature and can easily shatter. To overcome this, ORNL scientists developed an advanced electron-beam 3D printer that meticulously deposits tungsten layer by layer, forming precise three-dimensional structures. This innovative process uses a magnetically guided particle stream within a high-vacuum chamber to melt and fuse metal powder into a solid object, effectively minimizing contamination and residual stress.
"Electron-beam additive manufacturing shows great promise for creating intricate tungsten shapes," noted Michael Kirka of ORNL. "This development marks a significant advancement in utilizing temperature-resistant metals for energy resources, paving the way for a sustainable, carbon-free future."
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