Invention Reference Number
Oak Ridge National Laboratory has developed a new wire arc additive manufacturing (WAAM) technique that enables the crack-free deposition of pure tungsten metal. Tungsten is a critical material for applications such as plasma-facing components in fusion reactors but is notoriously difficult to process due to its brittleness. This method overcomes those challenges, allowing a layer of tungsten to be deposited without cracking. The innovation supports improved component repair and fabrication, reducing downtime and maintenance costs for advanced energy and industrial systems.
Description
This invention introduces a novel process for depositing pure tungsten using wire arc additive manufacturing (WAAM) while preventing cracking in both the deposited material and substrate. Tungsten’s high brittleness and elevated ductile-to-brittle transition temperature typically make it difficult to weld or repair, particularly in in-situ environments such as fusion reactor maintenance. The developed approach integrates a specialized preheating and deposition sequence that stabilizes the substrate temperature and controls thermal gradients throughout the additive process. By maintaining continuous operation of the heat source and adjusting key process parameters, the technique achieves smooth, defect-free tungsten layers across multiple beads or surfaces. This approach not only supports the repair of critical components but also enables the fabrication of complex tungsten structures that were previously impractical due to cracking limitations.
Benefits
- Enables crack-free deposition of pure tungsten using an additive manufacturing process
- Supports faster, in-situ repair of tungsten-based components
- Reduces material waste and maintenance downtime
- Improves manufacturability of high-performance, heat-resistant parts
Applications and Industries
- Fusion energy systems and plasma-facing components
- High-temperature materials manufacturing
- Advanced industrial repair and maintenance
- Aerospace and defense components requiring refractory metals
Contact
To learn more about this technology, email partnerships@ornl.gov or call 865-574-1051.
