Microstructure evolution of γ-Al2O3/FeAl tritium permeation barrier coatings under 6.4 MeV Fe3+ ion irradiation

γ-Al2O3/FeAl coatings for tritium permeation barrier (TPB) application in fusion reactors were fabricated via electro-chemical deposition and selective oxidation. The TPB coatings consisted of a γ-Al2O3 scale (200 nm), an upper interlayer of FeAl (20 μm) and a lower interlayer of Fe3Al (10 μm). Their potential in-reactor performance was investigated based on 6.4 MeV Fe3+ ion irradiations at 400 °C, up to ion fluences of 1.0 × 1019 ions·m−2 and 1.0 × 1020 ions·m−2, at depth regions entailing the oxide scale and the top interlayer. Combined grazing incidence X-ray diffraction (GIXRD) and transmission electron microscopy (TEM) analysis confirmed the overall phase stability and grain structure stability in γ-Al2O3/FeAl coatings after irradiation. Cavities dominated the damage microstructure for both γ-Al2O3 and FeAl phases, but were not observed at the sub-layer interfaces. The underlying mechanisms for defect production were discussed. Finally, a brief comparison between heavy-ion and fission neutron damage effects in Al2O3-based TPB coatings is made, aiming to bring new insights on the coating integrity and performance reliability during fusion reactor operation.