Extreme Heat Flux Research Articles

Recent progress in the development of liquid metal plasma facing components for magnetic fusion devices

One of the most critical challenges for future fusion reactors is to develop longevity plasma-facing components (PFCs) exposed to extremely high heat and neutron loads. As opposed to those employing solid metals, PFCs with flowing liquid metals (LM) have shown self-healing, heat removal and good impurity control capabilities, all essential to fusion devices. Recently, significant progress in LM-PFC development has been reported globally, with data from several magnetic fusion devices. These studies reveal that LM-PFCs can endure extreme heat fluxes while maintaining plasma compatibility. New design concepts have been proposed and numerically analyzed, advancing models for liquid PFCs in future reactors. Despite existing technical challenges, these developments suggest that LM-PFCs hold promise for future fusion applications.

Silica Aerogel-Modified Polyacrylonitrile Nanofibers to Reduce Heat Flux in Heat Storage Tanks of Greenhouse Buildings.

Polyacrylonitrile (PAN) nanofibers have specific characteristics such as thermal insulation, weatherproofing, and sunlight resistance and therefore are appropriate to be applied as insulation materials for various industries, especially in greenhouse construction. The heat source in greenhouse buildings that operate independently in the heating network comes from heat storage tanks. In the present study, employing thermal field numerical simulations, we investigate the heat flux of a cylindrical heat storage tank with silica aerogel-modified PAN nanofibers as thermal insulation materials. The geometric scale of the tank body, thermal insulation material thickness, and outdoor temperature are optimized to improve thermal insulation. The significant discrepancy in heat flux at different parts of the heat storage tank leads to the extreme heat flux arising at the water-gas interface on the inner and outer walls. It is indicated that the heat flux distribution can be effectively ameliorated by modifying the scale of the tank body to retain the overall water temperature. In particular, effective insulation can merely be acquired when the thermal conductivity of the insulation material is below 3.3 W·m-1·K-1. Eventually, the heat storage tank is optimized to store 1400 L water at 100 °C with a radius of 0.6 m and a thermal insulation thickness of 50 mm at an outdoor temperature of -10 °C, which can maintain excellent thermal insulation for 8 and 24 h at 87.7 and 69.9 °C, respectively.

Re-entry rocket basic flow characteristics and thermal environment of different retro-propulsion modes

During the supersonic re-entry of multi-nozzle heavy rockets into the atmosphere, the basic flow state becomes increasingly complex due to the coupling effect between the retro-propulsion plumes and the freestream. A numerical method using the hybrid Reynolds-Averaged Navier-Stokes and Large Eddy Simulation (RES) method and discrete coordinate method is developed to accurately estimate the thermal environment. In addition, finite rate chemical kinetics is used to calculate the afterburning reactions. The numerical results agree well with wind tunnel data, which confirms the validity and accuracy of the numerical method. Computations are conducted for the heavy carrier rocket re-entry from 53.1 km to 39.5 km altitude with 180° angle of attack by using three different Supersonic Retro-Propulsion (SRP) modes. The numerical results reveal that these three SRP flow fields are all Short Penetration Models (SPM). As the re-entry altitudes decrease, both the plume-plume interaction and the plume-freestream interaction become weaker. The highest temperatures in the plume shear layers of the three SRP modes increase by 8.36%, 7.33% and 6.92% respectively after considering afterburning reactions, and all occur at a re-entry altitude of 39.5 km. As the rocket re-enters the atmosphere, the maximum heat flux on the rocket base plate of three SRP modes stabilizes at 290, 170 and 200 kW/m2 respectively, but the maximum heat flux on the side wall increases significantly. When the altitude declines to 39.5 km, the extreme heat flux of the three modes increase by 84.16%, 49.45% and 62.97% respectively compared to that at 53.1 km.

Experimental and numerical investigation of transpiration cooling with gradient porosity layout for the thermal protection of nose cone

Transpiration cooling with liquid phase change has been widely regarded as one of the most promising thermal protection technology for aerospace vehicles. However, when applied to the nose cone with small curvature radius, cooling failure may occur due to the extreme high heat flux and pressure at the stagnation point. In order to deal with this issue, a wedged-shaped nose cone structures with a gradient porosity layout is designed in this work to optimize the coolant distribution in the porous nose cone, and the corresponding transpiration cooling performance with liquid phase change is experimentally and numerically investigated. At last, to meet the thermal protection requirements under different flight conditions as best as possible, an orthogonal experiment and fuzzy gray analysis were carried out to optimize the particle diameter, porosity layout and division interval of the porous nose cone with gradient porosity layout, taking a specific flight condition as an example. The results obtained in this work showed that gradient porosity layout can significantly improve the cooling efficiency at the stagnation point and the temperature uniformity on the outer surface. The porosity has the highest impact on the cooling performance, while the division interval has little impact. By optimizing, the cooling efficiency at the stagnation point can reach 74.5%, and the maximum temperature difference is less than 500K.

Investigation into Stress Relaxation and Creep Rate of C47200 Copper Alloy

Copper alloys have high thermal conductivity, relatively high mechanical strength, and toughness over a wide range of temperature; hence they are highly sorted for complex structural applications that required extreme heat flux under load. Creep of materials is classically associated with time-dependent plasticity under a constant stress/load at an elevated temperature, often greater than the absolute melting temperature. This research is aimed to study the evaluation of stress and creep rate in copper, identifying the mechanisms at which copper can easily be exposed to stress and creep deformations in structures. A 12 mm diameter copper rod with the composition of 52.05 % CuO and 30.26 % SnO2 was procured locally. Samples from the procured rod were heat treated to 650°C for 30 minutes and cooled in the still air as well as inside the furnace. Creep test was carried out at 760uC with a constant load corresponding to an initial stress (between 1.5 MPa and 350 MPa) and stress relation was carried out on a 98 kN capacity stress relaxation frame (from 350 MPa to 300 MPa). Rockwell hardness test and metallographic analysis (at 200 mm) were also conducted on the heat treated and unheated control samples. It was established that heat treatment reduced the hardness property of stress relaxed copper, accelerated the stress relaxation process up to 60 %, speed up both primary creep rate and the tertiary creep rate as well altered the linear creep pattern and behaviour.

Comparison of heat transfer performance between liquid metal and aviation kerosene in the wall cooling channel of aero-engine

This paper explores the comparison of heat transfer performance between aviation kerosene and liquid metals in the engine wall cooling channel. The relative error between the experiment and simulation results is within 3 %, indicating that the simulation has good accuracy. Simulation results show that the temperature uniformity of liquid metal is much higher than that of n-decane, and the heat absorption uniformity of liquid metal has a higher correlation with the flow rate than with the temperature. For a specific heat flux and channel configuration, there is a matched inlet flow rate for n-decane to optimize cracking in the channel. Liquid metals and n-decane exist different optimal aspect ratios and rib thicknesses to optimize flow distribution homogeneity. Liquid metal is more suitable for wall cooling channel to recover energy under extreme flight conditions with high heat flux, because the disadvantages of n-decane cooling are more obvious under the extreme heat flux condition. Therefore, it is necessary to introduce suitable control means in the cooling channel to increase the chemical heat sink of n-decane. However, liquid metal does not need to consider such a complicated matching relationship, which may be another advantage of using liquid metal as a wall coolant.

Conditional analysis on extreme wall shear stress and heat flux events in compressible turbulent boundary layers

This study presents a comprehensive analysis on the extreme positive and negative events of wall shear stress and heat flux fluctuations in compressible turbulent boundary layers (TBLs) solved by direct numerical simulations. To examine the compressibility effects, we focus on the extreme events in two representative cases, i.e. a supersonic TBL of Mach number $M=2$ and a hypersonic TBL of $M=8$ , by scrutinizing the coherent structures and their correlated dynamics based on conditional analysis. As characterized by the spatial distribution of wall shear stress and heat flux, the extreme events are indicated to be closely related to the structural organization of wall streaks, in addition to the occurrence of the alternating positive and negative structures (APNSs) in the hypersonic TBL. These two types of coherent structures are strikingly different, namely the nature of wall streaks and APNSs are shown to be related to the solenoidal and dilatational fluid motions, respectively. Quantitative analysis using a volumetric conditional average is performed to identify and extract the coherent structures that directly account for the extreme events. It is found that in the supersonic TBL, the essential ingredients of the conditional field are hairpin-like vortices, whose combinations can induce wall streaks, whereas in the hypersonic TBL, the essential ingredients become hairpin-like vortices as well as near-wall APNSs. To quantify the momentum and energy transport mechanisms underlying the extreme events, we proposed a novel decomposition method for extreme skin friction and heat flux, based on the integral identities of conditionally averaged governing equations. Taking advantage of this decomposition method, the dominant transport mechanisms of the hairpin-like vortices and APNSs are revealed. Specifically, the momentum and energy transports undertaken by the hairpin-like vortices are attributed to multiple comparable mechanisms, whereas those by the APNSs are convection dominated. In that, the dominant transport mechanisms in extreme events between the supersonic and hypersonic TBLs are indicated to be totally different.

The electrical response of refractory carbon/carbon composites to high-temperature ablation: A pathway to embedded sensing in extreme environments

High-temperature ceramics and composites are essential for leading edges on next-generation high-speed aerospace vehicles, where the surfaces are expected to see extreme temperatures and heat fluxes. However, these materials are vulnerable to in-flight degradation arising from oxidation and ablation. Due to the extreme conditions encountered during flight, even slight changes in surface properties can profoundly affect aerodynamic performance and precipitate catastrophic failure. In-flight embedded sensing is therefore critical. Unfortunately, traditional sensors either prohibitively interfere with aerodynamics or cannot survive in-flight conditions. To overcome this challenge, we explore the material-as-the-sensor paradigm for extreme environment materials. Changes in the electrical properties of a refractory carbon/carbon (C/C) composite are used as an indicator of degradation. C/C composite strips were exposed to an oxyacetylene torch to represent oxidation and ablation expected during service, and the electrical impedance of the strips was measured before and after each exposure. It was found that ablation-induced damage has a clear impact on alternating current transport that scales with increasing exposure time and ablated volume. Equivalent circuit analyses were conducted in order to better understand the nature of ablation damage on transport characteristics; it was found that the resistance of the equivalent circuit increases with increasing torch exposure time and ablated volume. This study is an important proof-of-concept result for establishing embedded sensing techniques in next-generation extreme environments.

A new method for characterizing the heat transfer capacity of the divertor and high heat flux components

The divertor is usually exposed to extreme incident heat flux conditions in nuclear fusion engineering and its ability to remove the heat is extremely crucial for the safe operation of magnetic confinement nuclear fusion device. The evaluation of the heat removal capacity of the divertor has been always based on high heat flux (HHF) tests. Yet such methods are only available for the small size of experimental components, it is more difficult to compare under different loading and cooling conditions. In order to assess the heat removal capacity in real time and accurately, a new method was developed to characterize the heat removal capacity of the divertor and other high heat load components based on the cooling water thermal decay time constant, the time constants model has also been established. The thermal decay time constant was obtained by fitting the characteristic curves of the water temperature differences with time during the cooling phase of different components under HHF tests. This index is used to quantitatively analyze, characterize and evaluate the heat transfer capacity of the system of the divertor.

Experimental study of bubble growth on novel fin structures during pool boiling

Boiling heat transfer associated with phase change is perhaps one of the most efficient cooling methodologies to manage extreme heat flux due to its large latent heat. Fin structures are used to further increase the magnitude of boiling heat transfer from the heated surface and have shown better performance than flat surface heat sinks. This work aims to experimentally investigate the heat transfer performance of two fin structures, namely regular and modified fins, in a pool boiling facility. The modified hollow fin structure is designed to enhance the regular fin's heat transfer performance by adding an artificial nucleation site. Heat transfer rates and heat transfer coefficients of the two fin structures are estimated in atmospheric pressure conditions using deionized water and compared with the literature. The results show that the regular fin heat sink shows a better heat transfer rate than the plane surface, while the modified fin structure shows higher heat transfer performance than the regular fin. This is attributed to the additional nucleation sites on the hollow fin, a better rewetting phenomenon, and therefore a favorable bubble growth and release mechanism. Also, a multilayer perceptron artificial neural network with a back-propagation training algorithm is applied for modeling the bubble departure diameter concerning wall superheat and subcooling level to predict the bubble behavior from the artificial nucleation site.

Evaluation of Processes Related to Stratosphere–Troposphere Coupling in GEFSv12 Subseasonal Hindcasts

Abstract The representation of the stratosphere and stratosphere–troposphere coupling processes is evaluated in the subseasonal Global Ensemble Forecast System, version 12 (GEFSv12), hindcasts. The GEFSv12 hindcasts develop systematic stratospheric biases with increasing lead time, including a too strong boreal wintertime stratospheric polar vortex. In the tropical stratosphere, the GEFSv12 winds and temperatures associated with the quasi-biennial oscillation (QBO) tend to decay with lead time such that they underestimate the observed amplitudes; consistently, the QBO-associated mean meridional circulation is too weak. The hindcasts predict extreme polar vortex events (including sudden stratospheric warmings and vortex intensifications) about 13–14 days in advance, and extreme lower-stratospheric eddy heat flux events about 6–10 days in advance. However, GEFSv12’s ability to predict these events is likely affected by its zonal-mean circulation biases, which increases the rates of false alarms and missed detections. Nevertheless, GEFSv12 shows stratosphere–troposphere coupling relationships that agree well with reanalysis and other subseasonal forecast systems. For instance, GEFSv12 reproduces reanalysis relationships between polar vortex strength and the Northern Annular Mode in the troposphere. It also exhibits enhanced weeks 3–5 prediction skill of the North Atlantic Oscillation index when initialized during strong and weak polar vortex states compared to neutral states. Furthermore, GEFSv12 shows significant differences in Madden–Julian oscillation (MJO) amplitudes and enhanced MJO predictive skill in week 4 during easterly versus westerly QBO phases, though these results are sensitive to the level used to define the QBO. Our results provide a baseline from which future GEFS updates may be measured.

Development of pebble-based extruded carbon rods for extreme plasma heat flux environments

This work presents first experiments toward the development of continuously renewable (extrudable) pebble-based carbon rods for use as plasma-facing components in extreme steady-state plasma flux environments. The primary envisioned application of this work is a first wall that can survive long-term in future magnetic fusion power reactors while also improving recovery of the reactor fuel (tritium and deuterium atoms). Bench tests applying extreme steady-state front-surface heat loads of up to 50 MW/m2 are presented. Continuous pebble rod front-surface recession and intact pebble recovery are successfully demonstrated, at a rate of order 0.2 cm/s. Numerical simulations of the pebble rod front-surface recession are able to match observations reasonably well, indicating that the recession mechanism can be understood as occurring due to pebble thermal expansion and resulting shock and cracking of the inter-pebble binder. Tests of the pebble rod extrusion demonstrate that friction between the rods and the stainless steel extrusion channel is tolerably low (<50 N for the expected channel length) over a wide range of temperatures. Front-surface outgassing rates below 1000 Torr L/s/m2 are achieved, believed to be sufficiently low for use in magnetic fusion reactors. Initial parametric scans over pebble rod size and binder fraction to vary front-surface recession rates are presented.

Wall temperature effects on wall heat flux in high-enthalpy turbulent boundary layers

The wall temperature significantly varies the turbulent statistics and coherent structures in high-speed wall-bounded turbulence under the low-enthalpy condition. The present study set out to investigate whether this is also the case for high-enthalpy turbulent boundary layers that incorporate the chemical reactions of multi-species gas mixture. For that purpose, we perform direct numerical simulations for high-enthalpy turbulent boundary layers at the Mach number of 4.5 and the momentum Reynolds number of 2400 with three groups of wall temperature. Statistical results show that the effects of wall temperature on the mean flow properties are similar to those of low-enthalpy flows, and the chemical reactions only affect the mean temperature without leaving strong impacts on the statistics of velocity. The wall heat flux and the physical processes thereof are further analyzed. The mass diffusion effects are increased by the rising wall temperature due to the more sufficient dissociation of the molecules. The wall heat flux fluctuations are also slightly enhanced, with the lower skewness and the higher kurtosis, and show more prominent structures of traveling wave packets and weaker streaks, as well as the less coherent vortices in the vicinity of the extreme positive wall heat flux events. The organizations of the mass species are also altered substantially by the rising wall temperature due to the stronger impacts of chemical reactions on the flow dynamics.

A compact LWIR borescope sensor for 2D engine component surface temperature measurement

A compact long-wavelength infrared (LWIR) borescope imaging sensor operating in the wavelength range of 8–14 μm is designed and developed for non-contact two-dimensional (2D) surface temperature measurements in gas-turbine engines. The LWIR detection minimizes optical interferences from hot combustion gases and soot (emission within UV–mid IR region). Using simulations, the system is optimized for improving the signal collection efficiency and minimize image aberrations. The LWIR borescope probe is shielded by the custom-build compact water-cooled probe housing (outer diamter (OD) 19 mm, inner diameter (ID) 10 mm), which can sustain flame temperature up to 2400 K at a pressure of 50 bar. It facilitates long-term optical diagnostics inside the actual high-pressure combustion facilities where extreme thermal acoustic perturbation and intense heat fluxes are encountered. The design, construction, and characterization of the LWIR borescope sensor are discussed in detail. We present the 2D surface temperature measurements of a V-gutter bluff-body with simple nitrogen gas cooling in a laboratory testbed. The results indicate the sensor’s ability to accurately measure surface temperature with low background noise and to track transient cooling effect. The water-cooled probe housing was tested to verify the effectiveness of fast heat dissipation in high-temperature combustion environment to avoid unwanted thermal signals from the LWIR probe window. The developed LWIR sensor suite has promising applications in surface temperature measurements of engine components. The findings of this study may aid propulsion system engineers and researchers in designing thermal management systems and optimizing operation.

In situ melting phenomena on W plasma-facing components for lower divertor during long-pulse plasma operations in EAST

Tungsten (W) is one of the most promising plasma-facing materials for future fusion devices. Although its melting point is the highest among all metals, it still has great risk of melting under extremely high plasma heat fluxes, which is a big concern for ITER and future reactors. Actively cooled W plasma-facing components (PFCs) with both monoblocks and flat-type structure have been successfully installed in the lower divertor of the EAST tokamak since 2021, and provide a good opportunity for direct comparison of the damage mechanism for the two types of PFCs. Various in situ melting phenomena on the lower divertor have been observed by CCD cameras, which have been further verified by post-mortem inspections. Severe melting and even exfoliation of the edge-beveled W plates were observed on some W/Cu flat-type components at horizontal outer targets. Many droplets were ejected during long-pulse operations, which induced a significant increase of W impurities and total irradiation in the core plasma, and thus greatly deteriorated the plasma performance and even caused disruptions. Two different shaping structures of flat-type PFCs show different positions of melting and the corresponding mechanisms. Slight melting was found on the sharp leading edges of W/Cu monoblocks between cassette modules (inter-CM) for horizontal targets with small droplet ejection, which was much improved compared to that observed on the upper W divertor, illustrating that the application of a large-sized bevel chamfer inter-CM was generally effective. In addition, an unexpected melting phenomenon on the dome plate was attributed to the extreme transient heat flux during disruption with runaway electrons. The application of both types of W/Cu PFCs for the divertor provides important experiences and lessons for the engineering design and optimization of divertor PFCs in future fusion devices.

Techno-economic feasibility analysis of an extreme heat flux micro-cooler

An estimated 70% of the electricity in the United States currently passes through power conversion electronics, and this percentage is projected to increase eventually to up to 100%. At a global scale, wide adoption of highly efficient power electronics technologies is thus anticipated to have a major impact on worldwide energy consumption. As described in this perspective, for power conversion, outstanding thermal management for semiconductor devices is one key to unlocking this potentially massive energy savings. Integrated microscale cooling has been positively identified for such thermal management of future high-heat-flux, i.e., 1kW/cm2, wide-bandgap (WBG) semiconductor devices. In this work, we connect this advanced cooling approach to the energy impact of using WBG devices and further present a techno-economic analysis to clarify the projected status of performance, manufacturing approaches, fabrication costs, and remaining barriers to the adoption of such cooling technology.

Transmission and Reflection of Upward-Propagating Rossby Waves in the Lowermost Stratosphere: Importance of the Tropopause Inversion Layer

Abstract Extreme stratospheric vortex states are often associated with extreme heat flux and upward wave propagation in the troposphere and lower stratosphere; however, the factors that dictate whether an upward-directed wave in the troposphere will reach the bottom of the vortex versus being reflected back to the troposphere are not fully understood. Following Charney and Drazin, an analytical quasigeostrophic planetary-scale model is used to examine the role of the tropopause inversion layer (TIL) in wave propagation and reflection. The model consists of three different layers: troposphere, TIL, and stratosphere. It is shown that a larger buoyancy frequency in the TIL leads to weaker upward transmission to the stratosphere and enhanced reflection back to the troposphere, and thus reflection of wave packets is sensitive not just to the zonal wind but also to the TIL’s buoyancy frequency. The vertical–zonal cross section of a wave packet for a more prominent TIL in the analytical model is similar to the corresponding wave packet for observational events in which the wave amplitude decays rapidly just above the tropopause. Similarly, a less prominent TIL both in the model and in reanalysis data is associated with enhanced wave transmission and a weak change in wave phase above the tropopause. These results imply that models with a poor representation of the TIL will suffer from a bias in both the strength and phase of waves that transit the tropopause region.

Intra-Lid Multi-Core Vapor Chamber Architecture for Heterogeneous Electronic Packages: Technology Concept to Prototype Evaluation

Thermal management of future heterogeneous electronic packages with extreme heat fluxes relies on effective spreading of heat in the package lid. Intra-lid integration of vapor chambers is a promising strategy for simultaneous dissipation of large total heat loads and localized high-flux hot spots. However, conventional vapor chambers comprising a single vapor core require relatively thick evaporator wicks to prevent dry out at high total heat loads, thereby imposing a large temperature drop across the wick at the hot spot location. We recently proposed a cascaded multi-core vapor chamber (CMVC) architecture comprising a single-core vapor chamber stacked on an array of smaller footprint vapor cores having relatively thinner wicks. The multi-core array is designed to spread heat from arbitrarily distributed high-flux hot spots before they enter the top vapor chamber having a thicker wick. Then, the top vapor chamber spreads the high total heat loads to the base of the mounted heat sink. To evaluate the proposed CMVC technology, we make a weighted decision to identify an appropriate minimum viable prototype for subsequent design and testing. A reduced-order model is used to determine the dimensions and properties of the wick and vapor core that minimize the temperature drop across the down-selected multi-core vapor chamber architecture for a given power map, considering manufacturing process constraints. Finite element analysis (FEA) simulations are employed to decide a condenser wall thickness that avoids permanent deformation in the vapor chamber architecture under a mechanical load. A prototype is manufactured by a commercial vendor following these parameters and manufacturing constraints. As predicted by the thermal model, experimental characterization of this first-reported multi-core vapor chamber array prototype offers a notable reduction in temperature drop relative to a benchmark solid copper spreader, owing to attenuation of hot spots at a low temperature difference.

Topology optimization of supports with imperfect bonding in additive manufacturing

Supports are an important ingredient of the building process of structures by additive manufacturing technologies. They are used to reinforce overhanging regions of the desired structure and/or to facilitate the mitigation of residual thermal stresses due to the extreme heat flux produced by the source term (laser beam). Very often, supports are, on purpose, weakly connected to the built structure for easing their removal. In this work, we consider an imperfect interface model for which the interaction between supports and the built structure is not ideal, meaning that the displacement is discontinuous at the interface while the normal stress is continuous and proportional to the jump of the displacement. The optimization process is based on the level set method, body-fitted meshes and the notion of shape derivative using the adjoint method. We provide 2-d and 3-d numerical examples, as well as a comparison with the usual perfect interface model. Completely different designs of supports are obtained with perfect or imperfect interfaces.

Demonstrating tungsten fiber-reinforced porous-matrix tungsten composites for future fusion application

Tungsten fiber-reinforced tungsten (Wf/W) has been developed to improve the fracture toughness of W materials, as demonstrated in previous studies (2019 Nucl. Fusion 59 086034; 2021 Mater. Sci. Eng. A 817 141361). In the present study, we focus on the performance of the developed Wf/W materials under fusion-relevant test conditions and further demonstrate their use as plasma facing materials in future fusion reactors. Specifically, one set of Wf/W samples was exposed to Ne plasma to investigate the erosion resistance against plasma sputtering, in comparison to the reference ITER-grade W sample. In addition, deuterium (D) retention in the plasma-exposed Wf/W samples was studied via thermal desorption spectroscopy. Furthermore, laser thermal shock tests were performed on Wf/W to simulate the transient heat load condition and to investigate the material performance under extreme heat flux. With increasing porosity, Wf/W exhibits lower mass loss (net erosion) after Ne plasma exposure. Though porous, Wf/W composites unexpectedly show a comparable D retention to the reference bulk W, which is attributed to the openness of the pores in the matrix. Thermal shock testing results indicate a similar cracking threshold (0.38 GW m−2, 1 ms) as compared with that of ITER-grade W materials. However, due to the lower thermal conductivity of porous matrix Wf/W, under extremely high loading conditions (1.6 GW m−2, 2 ms) surface melting was observed. The present work demonstrates the great potential of the porous matrix Wf/W for future fusion application.