Directed energy deposition of functionally graded V-4Cr-4Ti to Fe-9Cr transition for fusion power systems

• • Demonstrated additive manufacturability of three unique alloys for the first time. • • Developed a processing roadmap for near defect-free multi-material fabrication. • • A multilayer VCrTi-Gr91 graded part was printed for fusion divertor components. • • Minor cracking at FeCrAl-VCrAl interface was linked to an FeV intermetallic formation. • • Discrete Cr buffer layer integration to mitigate intermetallic formation is proposed. This study proposes a graded structure via additive manufacturing for divertor and first wall blanket applications in fusion reactors. Materials were selected based on thermodynamic calculations to operate from 1100 °C at the plasma-facing level to 550 °C at the structural steel level. Conventional joining methods often lead to failures due to discrete reaction layers with significant mechanical property differences. Using laser beam-directed energy deposition (LB-DED), this study demonstrates the fabrication of a VCrTi-Gr91 steel functionally graded component through a novel process parameter optimization framework. A systematic approach included powder characterization, single-track depositions, and construction of printability maps. Near full-density specimens of each interlayer were additively manufactured, and a transition from V-based alloys to reduced activation ferritic martensitic steels was achieved. Computational material selection of interlayer alloys and thermodynamic/diffusion kinetics simulations prevented most interface incompatibilities. A brittle intermetallic formed at one interface, causing cracking, which was not predicted by current thermodynamic models. Transition alloy design approach was updated with a more recent database and a mitigation strategy has been proposed to eliminate the formation of deleterious intermetallic phases. Ultimately, LB-DED has proven effective for producing multi-material graded systems for fusion applications, with the demonstrated process parameter optimization framework applicable to various materials.