Optimizing Plasma Spraying Process Parameters for Tungsten Coatings Used in Fusion Reactors

The quality of low-pressure plasma-sprayed tungsten (W) coatings for application in fusion reactors was investigated under various spray process parameter settings for the following substrate materials: carbon fiber composite, Eurofer (a ferritic/martensitic steel with reduced activation), and tungsten. The deposited coatings with a thickness of approximately 130 µm were evaluated in terms of porosity, deposition efficiency, defects, and surface roughness. Selected parameter sets were applied to produce scaled-up coatings up to 500 µm in thickness on Eurofer and tungsten substrates. Regions of very low porosity of approx. 0.3