In the course of developing functionally graded tungsten/steel-layer systems as protective coatings for the first wall (FW) of future fusion reactors, an overview of the results attained so far is given. This includes the determined parameters for creating such systems by vacuum plasma spraying on a laboratory scale and the achieved material properties determined in previous works. To realize the coating of future full scale FWs as well, the coating process is adapted to larger coating areas in the form of mock-ups. For such components, special attention needs to be paid to the challenges of the limited temperature window during coating to achieve good coating adhesion, whilst avoiding exceeding the tempering temperature of the steel. One successfully coated mock-up is also exposed to fusion-relevant heat loads in HELOKA (Helium Loop Karlsruhe) to evaluate the coating system behavior and verify its durability. Finally, for even larger components the coating design and process are further optimized, supported by finite element simulations.
摘 要 在开发用于未来聚变反应堆第一壁（FW）保护涂层的功能梯度钨/钢层系统过程中，本文概述了迄今为止所取得的成果。这包括通过真空等离子喷涂在实验室规模下制备此类系统的工艺参数，以及先前工作中获得的材料性能。为了实现未来全尺寸第一壁的涂层，将涂层工艺扩展到更大的涂层面积，并以模拟件（mock-up）形式进行验证。对于此类部件，需要特别关注涂层过程中有限温度窗口带来的挑战，以确保良好的涂层附着力，同时避免超过钢的回火温度。一个成功制备的模拟件还接受了HELOK（卡尔斯鲁厄氦冷却回路）中与聚变相关热负荷的测试，以评估涂层系统的行为并验证其耐久性。最后，针对更大的部件，结合有限元模拟对涂层设计和工艺进行了进一步优化。