Abstract
Tungsten is a refractory metal with the highest melting temperature and density of all metals in this group. These properties, together with the high thermal conductivity and strength, make tungsten the ideal material for high-temperature structural use in fusion energy and other applications. It is widely agreed that the manufacture of components with complex geometries is crucial for scaling and optimizing power plant designs. However, there are challenges associated with the large-scale processing and manufacturing of parts made from tungsten and its alloys which limit the production of these complex geometries. These challenges stem from the high ductile-to-brittle transition temperature (DBTT), as well as the strength and hardness of these parts. Processing methods, such as powder metallurgy and additive manufacturing, can generate near-net-shaped components. However, subtractive post-processing techniques are required to complement these methods. This paper provides an in-depth exploration and discussion of different processing and manufacturing methods for tungsten and identifies the challenges and gaps associated with each approach. It includes conventional and unconventional machining processes, as well as research on improving the ductility of tungsten using various methods, such as alloying, thermomechanical treatment, and grain structure refinement.
Highlights
The demand for electricity is increasing at an unprecedented rate
This study demonstrated that the surface quality of porous tungsten can be controlled by careful consideration of machining parameters, including the cutting speed, rake angle, and pre-cooling temperature
The challenges of producing tungsten and tungsten alloy parts with complex geometries and required tolerances have been reviewed with respect to current production routes
Summary
Worldwide economic growth and an increasing global population are expected to result in a doubling of global electricity consumption by 2040. The electricity share of the total final energy consumption is expected to increase from 19% in 2018 to 24% in 2040 [1]. According to the recent United Nations Environment Programme (UNEP) emissions gap report, these ambitious targets are not without barriers. Even if these targets were met, the global temperature rise from pre-industrial levels is still on course to be more than 3 ◦C this century—well beyond the 2 ◦C or the ideal 1.5 ◦C set in the Paris agreement [4]. Technological innovations and sustained policy interventions are urgently required on a global scale to reverse this trend
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