Vanadium alloy to tungsten armour joining for fusion first-wall/blanket & plasma-facing components

A funded 3.5-year UK PhD studentship is available at the University of Birmingham with a tax-free stipend. The project is co-funded by Tokamak Energy and in collaboration with the Electric Power Research Institute (EPRI), USA, and Forschungszentrum Jülich, Germany. Background: Tungsten (W) is the leading candidate for plasma-facing components in future fusion reactors due to its high melting point, low sputter yield, and excellent thermal conductivity [1]. However, integration of W armour to structural materials in the first-wall (FW)/blanket remains a challenge due to the absence of robust dissimilar metal joining technologies. In Tokamak Energy’s fusion pilot plant design, vanadium (V) alloys, especially V-4Cr-4Ti (V44), is the preferred FW/blanket structural material due to its outstanding thermal creep properties, liquid lithium compatibility, high thermal conductivity, and low neutron absorption [2]. Thus, reliable W/V joining is critical for system operability. While W/V joints have a lower coefficient of thermal expansion (CTE) mismatch than W/steel, the manufacturing readiness level remains low. Solid-state welding without interlayers may be viable due to closer CTE match [3], but their application in high-load fusion environments needs rigorous analysis [4]. Brazing is another potential technique, particularly for complex geometries, though existing data highlight challenges such as V44 substrate embrittlement during joining—likely due to grain growth and/or precipitate dissolution at elevated temperatures [5]. Diode laser cladding may offer advantages for scalable production. Currently, little data exists on the thermomechanical performance of W/V joints via these methods. Understanding the link between microstructure and properties is crucial for process optimisation and design integration. Project Scope: This PhD will conduct a parametric study of dissimilar W/V joining. Techniques of interest include diffusion bonding, brazing, and diode laser cladding. The research will establish structure–property relationships through advanced electron microscopy and mechanical testing, including tensile strength, fracture toughness, and thermal creep. Samples will undergo high-heat flux (HHF) testing for thermal fatigue and shock resistance. You will access cutting-edge HHF testing facilities, such as Tokamak Energy’s PREFACE electron-beam setup (steady-state heat loads up to ~45 MW/m²), and the JUDITH-II facility at Jülich (transient loads up to ~1 GW/m²). Computational modelling tools will complement the experimental work to guide joining strategies and post-weld heat treatment protocols. The outcomes will support selection of a joining technique for Tokamak Energy’s pilot plant and provide thermomechanical property data to inform FW/breeder blanket engineering design models. Supervision and Collaboration: You will be based at the University of Birmingham, working closely with researchers from Tokamak Energy, EPRI, and Jülich. The project offers a collaborative, inclusive, and innovative research environment dedicated to tackling global challenges such as sustainable fusion energy. You will receive strong mentorship to help build a successful post-PhD career. Candidate Profile: Applicants should hold a first or upper-second-class degree in materials science, mechanical, chemical, nuclear or aerospace engineering, or physics (including plasma or condensed matter). Prior experience in microstructural characterisation or fusion/fission concepts is beneficial but not essential. We seek a curious, motivated, and committed individual. Contact: For further information, contact any of the researchers below: • Prof. Arunodaya Bhattacharya (a.bhattacharya.1@bham.ac.uk) • Prof. Moataz Attallah (m.m.attallah@bham.ac.uk) • Dr. Samara Michelle Levine (samara.levine@tokamakenergy.com) Please include your CV and academic transcripts when reaching out. #J-18808-Ljbffr