The development of polymers, traditionally neglected in fusion materials research, is crucial to the success of commercial fusion energy. This article provides an overview of the materials science and technology challenges that will need to be addressed to develop the mechanically “soft” materials that will serve functional needs in a fusion pilot plant.

Enhancement of the diffusion bonding process for the development of compact heat exchangers (CHXs) provides an energy efficient solution for high-temperature applications in advanced nuclear reactors and other technologies. However, available information is limited concerning the diffusion bonding (and manufacturing) of CHXs in high temperature applications and associated selection of bonded materials, bonding conditions, mechanical performance, and thermo-fluid characteristics. This article reviews the available knowledge and the ongoing research being conducted to address gaps in information and application.

Cold spraying is a potentially attractive method for producing accident tolerant fuel cladding, near-net shape nuclear reactor components, and nuclear fuel storage canisters.

Radio frequency inductively coupled plasma (RF-ICP) spraying is shown to be a promising method for producing oxidation-resistant W and W-Cr coatings on plasma-facing surfaces in fission and fusion reactors.

Development of new, radiation-tolerant materials that maintain the structural integrity and safety margins over the course of a nuclear power reactor’s service life requires the ability to predict degradation phenomena. Modern post-irradiation examination methods make use of specialized high-flux test reactors and dedicated characterization facilities to limit occupational exposure and prevent the spread of radioactive contamination. This article illustrates the use of these advanced techniques to characterize precipitates in neutron-irradiated Fe-Cr-Al alloys.

This article describes work being done at the University of Limoges to develop thermal spray coatings for use in new nuclear power plant designs.

The corrosion of structural materials and control of coolant chemistry are key factors that impact the lifetime of nuclear reactors and the development of future reactors. This article reviews corrosion issues in four reactor concepts that use vastly different coolant types: light water reactors, lead fast reactors, high temperature gas-cooled reactors, and fluoride salt-cooled high temperature reactors.

Researchers at Pacific Northwest National Laboratory (PNNL) use a combination of scanning and transmission electron microscopy, atom probe tomography, and focused ion beam milling to analyze corrosion and crack structures in light-water reactor components with near-atomic spatial resolution.

A novel brazing approach for joining SiC-based fuel cladding is a promising technology for enhanced accident-tolerant nuclear fuels.