2026/07/20 by Thomas Barzic, Anna-Carina Seitlinger, Christoph Frühwirth +10
#cond-mat.mtrl-sci #physics.plasm-ph
Commercial fusion energy requires materials that survive intense neutron bombardment whilst extracting extreme heat loads for conversion to electricity. The CuCrZr alloy, the leading heat-sink material for fusion reactors, derives its strength from a fine dispersion of nano-precipitates formed during prime-ageing heat-treatment. Whether this precipitation-hardening strategy can withstand fusion-relevant irradiation remains untested. Here we show, combining in situ transmission electron microscopy under heavy-ion irradiation and He implantation with thermodynamic and transmutation modelling, that the hardening precipitates dissolve under two opposing kinetic regimes: ballistic dissolution dominates at low temperatures, whilst dissolution and re-precipitation dominate at high temperatures. Although the accelerated dose rates inherent to ion irradiation shift the balance between ballistic mixing and thermal back-diffusion relative to reactor conditions, precipitate degradation at both kinetic extremes indicates that the prime-aged microstructure is unlikely to remain unaltered under prolonged neutron exposure. He bubbles and Kr-rich voids nucleate once vacancies become mobile, and transmutation over five service years irreversibly redirects the alloy chemistry towards Ni-Zr intermetallics. These three independent mechanisms converge to challenge the strategy on which CuCrZr performance depends, suggesting that the long-term performance of age-hardenable Cu-based heat-sink alloys in fusion reactors warrants further assessment. Our findings reveal a new materials challenge for fusion reactor design and commercialisation: the need for new Cu-based heat-sink alloys able to retain engineered strength whilst their chemistry is irreversibly rewritten - thermodynamically and ballistically - by the fusion neutron spectrum.