Tungsten Alloy Research Articles

The dosimetric accuracy of a commercial model-based dose calculation algorithm in modeling a six-groove direction modulated brachytherapy tandem applicator

Objective.With advancements in high-dose rate brachytherapy, the clinical translation of intensity modulated brachytherapy (IMBT) innovations necessitates utilization of model-based dose calculation algorithms (MBDCA) for accurate and rapid dose calculations. This study uniquely benchmarks a commercial MBDCA, BrachyVision ACUROSTM(BVA), against Monte Carlo (MC) simulations, evaluating dose distributions for a novel IMBT applicator, termed as thesix-grooveDirection Modulated Brachytherapy (DMBT) tandem, expanding beyond previous focus on partially shielded vaginal cylinder applicators, through a novel methodology.Approach.The DMBT tandem applicator, made of a tungsten alloy with six evenly spaced grooves, was simulated using the GEANT4 MC code. Subsequently, two main scenarios were created using the BVA and reproduced by the MC simulations: 'Source at the Center of the Water Phantom (SACWP)' and 'Source at the Middle of the Applicator (SAMA)' for three cubical virtual water phantoms (20 cm)3, (30 cm)3, and (40 cm)3. A track length estimator was utilized for dose calculation and 2D/3D scoring were performed. The difference in isodose surfaces/lines (i.e. coverage) at each voxel,ΔDIsodose Levels/Lines, was thus calculated for relevant normalization points (rref).Results.The coverage was comparable, based on 2D scoring, between the BVA and MC isodose surfaces/lines for the region of clinical relevance, (i.e. within 5 cm radius from the source) withΔDIsodose Lines(rref: 1 cm from the source) falling within 2% for the two scenarios for all phantom sizes. For the phantom (20 cm)3,ΔDIsodose Levels(3D scoring) recorded the range [-3.0% +6.5%] ([-7.4% +7.3%]) for 95% of the voxels of the same scoring volume for the SACWP (SAMA) scenario.Significance.The results indicated that the BVA could render comparable coverage as compared to the MC simulations in the region of clinical relevance for different phantom sizes.ΔDIsodose Linesmay offer an advantageous metric for evaluation of MBDCAs in clinical setting.

A First-Principles Study of the Structural and Thermo-Mechanical Properties of Tungsten-Based Plasma-Facing Materials

Tungsten (W) and tungsten alloys are being considered as leading candidates for structural and functional materials in future fusion energy devices. The most attractive properties of tungsten for the design of magnetic and inertial fusion energy reactors are its high melting point, high thermal conductivity, low sputtering yield, and low long-term disposal radioactive footprint. Despite these relevant features, there is a lack of understanding of how the structural and mechanical properties of W-based alloys are affected by the temperature in fusion power plants. In this work, we present a study on the thermo-mechanical properties of five W-based plasma-facing materials. First-principles density functional theory (DFT) calculations are combined with the quasi-harmonic approximation (QHA) theory to investigate the electronic, structural, mechanical, and thermal properties of these W-based alloys as a function of temperature. The coefficient of thermal expansion, temperature-dependent elastic constants, and several elastic parameters, including bulk and Young’s modulus, are calculated. Our work advances the understanding of the structural and thermo-mechanical behavior of W-based materials, thus providing insights into the design and selection of candidate plasma-facing materials in fusion energy devices.

Laser powder bed fusion in-situ alloying of W-Y alloy: Microstructure, mechanical properties and cracking suppression

The microcracks caused by impurity oxygen are recognized as one of the main challenges in additive manufacturing of tungsten. In this study, yttrium was incorporated into the tungsten matrix to suppress crack formation, and W-Y alloys with minimal cracks were successfully obtained by laser powder bed fusion (LPBF). It is found that during the LPBF process, yttrium combines with impurity oxygen to generate intergranular and intragranular precipitated particles in situ, which effectively suppress cracking behavior due to impurity oxygen. Furthermore, these intracrystalline nanoprecipitate are cubic Y2O3 particles that have formed a semi-coherent interface with the tungsten matrix. These dispersed particles significantly improved the mechanical properties of W-Y alloy. The results offer a corresponding strategy for crack suppression of tungsten alloys in laser additive manufacturing processes, and would provide a benificial additive manufacturing strategy to other refractory alloys.

Exceptional Low Temperature Fabrication of Self-Passivating Tungsten Alloys by Mechanical Alloying and Spark Plasma Sintering

Exceptional Low Temperature Fabrication of Self-Passivating Tungsten Alloys by Mechanical Alloying and Spark Plasma Sintering

Minor tungsten addition enhances corrosive resistance in CoCrFeNi high-entropy alloy at elevated seawater temperature

Most research on the corrosive CoCrFeNi high-entropy alloy (HEA) has mainly modulated element species and atomic concentration recently. However, the corrosive resistance of the passive film in the elevated temperatures environment inevitably need to be extensively explored for application. In this work, the microstructure and corrosion behavior in the elevated temperatures of face-centered cubic (FCC) CoCrFeNiWx (x = 0 and 0.2) HEAs are investigated. The mechanism of passivation layers on the corrosion behavior of HEAs is further discussed for comparison to the alloy of addition tungsten. Through potentiodynamic polarization curves in 3.5 wt% NaCl solution from 25 °C to 70 °C, the addition of tungsten can raise the critical pitting temperature, while maintaining a lower passivation current density and a larger passivation range at the same time. The high resolution X-ray photoelectron spectrometer (HRXPS), electrochemical impedance spectroscopy (EIS) and scanning electrochemical microscopy (SECM) are all conducted to analyze the passivation composition and chemical reaction of the present alloys detailly. The CoCrFeNiW0.2 HEA exhibits the uniform Cr2O3 layer on the FCC matrix; the proportion of dispersive WO3 layer on the μ phase precipitates form a double-layer passive film under elevated temperature in 3.5 wt% NaCl. It shows that the synergistic effect of the double-layer passive film significantly enhances the pitting and corrosive resistance in this HEA.

Heterogeneous phase deformation in a dual-phase tungsten alloy mediated by the tungsten/matrix interface: insights from compression experiments and crystal plasticity modeling

Tungsten heavy alloy (WHA) is a typical multiphase alloy material consisting of hard tungsten (W) and soft matrix (γ) phases. When loaded, the two phases deform quite differently due to the large difference in their mechanical properties. At present, our understanding of phase deformation and behavior in the multiphase context is relatively poor compared to the single phase case. Such insight is necessary, however, for the design of multiphase alloys having optimal phase microstructure and corresponding material behavior. By combining mechanical testing and crystal plasticity modeling, the relationship between phase microstructure and multiphase alloy deformation behavior is systematically investigated in this work. The results demonstrate that deformation in the W and γ phases is quite different and related to the contrast in material properties between the two phases. Deformation heterogeneity in the multiphase alloy is characterized by the strain gradient near/across the W/γ interface and differences in phase deformation states in relation to the contrast in phase material properties and phase volume fraction. It is found that dislocation pile-up and twinning are the main mechanisms mediating heterogeneous deformation in the region around W/γ interfaces. Based on this insight, a novel design strategy for multiphase alloys is proposed based on optimization of the contrast in phase mechanical properties and the phase volume fractions. This strategy can be employed to design new tungsten alloys and other multi-phase alloys.

Microstructure evolution and mechanical properties of tungsten alloy prepared by laser directed energy deposition

Tungsten heavy alloys (WHAs) are widely applied across military, medical, and other advanced industries. Laser-directed energy deposition (LDED) is an innovative approach to fabricate WHAs with intricate microstructures. This study explored the manufacturing processes and forming characteristics of three distinct tungsten alloy compositions to elucidate the microstructural formation mechanisms and performance evolution of WHAs prepared by LDED. Electron backscatter diffraction analysis revealed the occurrence of heterogeneous nucleation and dendritic precipitation in supersaturated solid phases across different alloy compositions. By applying the drag force equation derived from the two-phase flow theory, the Gaussian energy distribution inherent to the LDED process, and the low flowability of WHAs, this study reveals the microstructural layering mechanisms within LDED-produced samples. Through process optimization, 90W samples that exhibited an ultimate tensile strength of 1093MPa and elongation of 16.8% were obtained. In situ mechanical testing revealed that the reduced elongation of the WHAs produced by LDED is due to their unique fracture mechanism driven by the interconnection of cracks between fractured tungsten particles. However, by incorporating smaller W particles and optimizing the gap ratio, the stress concentration can be effectively mitigated and crack propagation can be curtailed, thereby significantly enhancing elongation.

Excellent radiation resistance via enforced local non-directional He diffusion in a WTaCrV multicomponent alloy containing coherent ordered nanoprecipitates

We design and investigate a W15Ta15Cr35V35 (at.%) multicomponent alloy (MCA) with exceptional radiation resistance. The sintered WTaCrV alloy exhibits a body-centered cubic (BCC) matrix with dispersed coherent ordered nanoprecipitates. After ∼3-hour irradiation under 400 keV He+ at room temperature (RT) and 450°C with a fluence of 2 × 1017 ions/cm2, the irradiation hardening values of the MCA are about a quarter of those of pure tungsten counterparts irradiated at identical conditions. Besides, helium bubbles generated in the irradiated matrix of the MCA are much smaller, compared with those in the pure tungsten and other tungsten-rich alloys previously reported. The exceptional radiation resistance of the present WTaCrV alloy can be mainly attributed to two synergistic mechanisms. First, the high lattice distortion of the solid solution matrix promotes the local non-directional diffusion of irradiation defects, effectively suppressing the aggregation of irradiation defects and helium atoms along specific orientations. This facilitates more uniform nucleation of helium bubbles in the alloy matrix. Second, carbon was introduced during fast hot pressing sintering as interstitial solute to form carbon-rich coherent ordered nanoprecipitates. The carbon-vacancy complexes generated in the nanoprecipitates inhibit the nucleation and aggregation of helium atoms at the vacancies during He+ irradiation. The above two mechanisms synergistically enhance the resistance against He+ irradiation. This work thus demonstrates a design strategy for high radiation resistance alloys by introducing well-tuned ordered coherent nanoprecipitates in multicomponent alloy systems.

Tailored micro-arc oxidation coatings to match with parylene for enhanced tribological performance of Ta-12W alloys

To improve the tribological properties of tantalum-tungsten alloys, dual-layer composite coatings are designed using micro-arc oxidation (MAO) and chemical vapor deposition (CVD) techniques. By adjusting the concentrations of NaOH and NaF additives as well as the oxidation mode (constant current/voltage) of MAO process, the microstructure and properties of underlying MAO layers are tailored for better matching with the top parylene layer, aiming to develop composite coatings capable of service under heavy loads. A comprehensive study is conducted to evaluate the effect of these parameters on the growth, microstructure, bond strength, and mechanical properties of MAO coatings, along with their subsequent impact on the friction and wear behavior under various loads for composite coatings. The findings reveal that increasing the concentration of either NaOH or NaF significantly increases the coating thickness, surface porosity, crystallinity, and hardness of MAO coatings, by promoting the spark discharge activities. However, distinct interfacial growth behavior is observed due to anionic effects caused by OH− and F−. The oxidation mode plays a crucial role in determining the mechanical quality of coatings; the constant voltage mode facilitates dense coatings with high adhesion due to its self-repairing mechanism. Furthermore, wear tests confirm that the enhanced mechanical properties and open-porosity of the MAO coatings markedly improve the tribological performance of composite coatings. This improvement is attributed to the excellent load-bearing capacity provided by hard MAO layers, as well as the anchoring and storage capabilities of the textural porous surfaces. The optimized composite coating demonstrates long-lasting low friction even under heavy loads up to 80 N.

Neutron imaging of the deuterium-tritium tamping gas volume in an inertial confinement fusion hohlraum.

To benchmark the accuracy of the models and improve the predictive capability of future experiments, the National Ignition Facility requires measurements of the physical conditions inside inertial confinement fusion hohlraums. The ion temperature and bulk motion velocity of the gas-filled regions of the hohlraum can be obtained by replacing the helium tamping gas in the hohlraum with deuterium-tritium (DT) gas and measuring the Doppler broadening and Doppler shift of the neutron spectrum produced by nuclear reactions in the hohlraum. To understand the spatial distribution of the neutron production inside the hohlraum, we have developed a new penumbral neutron imager with a 12mm diameter field of view using a simple tungsten alloy spindle. We performed the first experiment using this imager on a DT gas-filled hohlraum and successfully obtained the spatial distribution of neutron production in the hohlraum plasma. We will report on the design of the spindle, characterization of the detectors, and methodology of the image reconstruction.

Mechanical properties and JC constitutive modification of tungsten alloys under high strain rates and high/low temperatures

The original Johnson-Cook model's poor prediction of W90 alloy stress at high strain rate and high and low temperatures restricts research and utilization of this alloy. This study used a Split Hopkinson Pressure Bar (SHPB) device to conduct dynamic compression tests on W90 alloy over a temperature range of [-90℃,700℃] and analyze its mechanical behavior. We examined the material's different plastic phase characteristics at high and low temperatures and conducted microstructure research on impact test specimens. Then, we analyzed the stress-strain data from SHPB experiments and quasi-static compression tests on the classical Johnson-Cook model. The original Johnson-Cook model was calibrated using the stress-strain data from SHPB and quasi-static compression tests, and the modified Johnson-Cook model was established and verified. The results show that: low temperature significantly strengthens the material's stress, while increasing temperature thermal softening reduces stress; increasing strain rate increases the strain generated by the workpiece, causing faster strain hardening and thermal softening effects, resulting in higher and more stable stress; low temperature makes thicker grain boundaries, increasing plastic stress, and increasing strain rate also increases plastic stress, as well as making the material's grain boundaries thicker. The increase of strain rate makes the grain more dense, which will also show up in the increase of stress on the macroscopic level; the modified Johnson-Cook model in this paper has high agreement with experimental data, with a mean value of MAPE of only 1.85 %,which is 90.20 % lower than the traditional model, and the average value of the RMSE is 85.56 % lower than the traditional model. The modified model significantly outperforms the traditional model in predicting stress and better describes stress changes in W90 at different temperatures.

Effect of Current Waveform on Microstructure Evolution and Mechanical Properties of GH4169 High-Temperature Alloy Tungsten Inert Gas Additive Manufacturing.

Direct current (DC) and pulsed DC tungsten inert gas (TIG) additive manufacturing processes were employed to fabricate GH4169 high-temperature alloy specimens. Upon comparing and analysing the two additive manufacturing methods, the evolution of microstructure and mechanical properties of the additively manufactured specimens were discussed. It provided a useful reference for the engineering application of pulsed DC TIG technology. The results showed that the overall forming process of the specimen was relatively stable under the DC TIG additive manufacturing and pulsed DC TIG additive manufacturing processes. The aspect ratio of the deposited layer of the pulsed DC-deposited specimen was relatively low, and the deposited layer of the pulsed DC specimen became flatter, which was conducive to maintaining the stability of the molten pool during the deposition process and improving forming accuracy. The microstructure distribution of the deposited layer from bottom to top was relatively uneven, with columnar dendrites in the bottom layer, cellular crystals in the middle layer, and equiaxed crystals in the top layer. Compared with the DC TIG additive manufacturing of GH4169 high-temperature alloy specimens, the Laves phase of the pulsed DC specimens was significantly reduced, which improved the plasticity and brittleness of the material.

Manufacturing of heavy tungsten alloys from nano-sized metal oxides via simultaneous reduction-sintering powder treatments

Heavy tungsten alloys are of great importance in the engineering and mining industries as well as the military and medical applications because of their stability at high temperatures, high strength and dense structures. The present study develops a novel technology for the production of heavy tungsten alloys via thermal treatment of nano-sized metal oxides based on simultaneous reduction and sintering processes. Heavy tungsten alloy (95W-3Ni-2Fe) was produced from the reduction of mixed nano-sized metal oxides precursor in H2 at 1000 o C followed by sintering at 1350–1450 o C for 30–90 min. The reduced and sintered samples were characterized by XRD to follow up the crystallinity, total porosity measurement was used to find out the densification properties, the grain structure and morphology were examined by RLM and SEM attached with EDAX. Micro-hardness tester was also used to investigate the influence of sintering conditions on the grain densification. A fundamental study on the kinetics of reduction of mixed nano-sized metal oxides precursor was performed by isothermal and non-isothermal techniques. Both results from isothermal and non-isothermal tests were used to calculate the activation energy which was correlated with macro- and micro-structures to predict the corresponding reduction mechanism. However, the influence of sintering temperature and time on the crystallinity of the produced phases, grain structure, morphology, total porosity, pore-size distribution, bulk and apparent densities, and the hardness of sintered compacts was extensively investigated. The results revealed that the presence of NiO and/or Fe2O3 in the mixed metal oxides precursor was very important to ease the reducibility of WO3 as the metallic phases of Ni and/or Fe act as a catalyst for the reduction of WO3. The rate of reduction proceeds faster in the following order: NiO > Fe2O3 > mixed oxide > WO3. In non-isothermal experiments, it was found that the heating rate has a considerable effect on the reduction of precursor, i.e., the lower the heating rate, the higher the degree of reduction. It might be reported that the use of nano-sized metal oxides particles in the fabrication of heavy tungsten alloys greatly affects the main properties of the produced alloy. With the increase in sintering time, larger sizes of dense grains were developed, and the matrix became denser as a result of sintering and re-crystallization effects. The higher the sintering time, the higher the grain densification and the less pores formed in the matrix. On the other hand, with the increase in the sintering temperature, the grain boundaries were well defined in which the grains were composed of tungsten metal and surrounded by inter-metallics. The higher the temperature, the higher the XRD peak intensities of metallic tungsten and intermetallics as a result of sintering and re-crystallization.

Research Progress on Rolling Forming of Tungsten Alloy.

Tungsten is a metal with many unique characteristics, such as a high melting point, high hardness, high chemical stability, etc. It is widely used in high-end manufacturing, new energy, the defense industry, and other fields. However, tungsten also has room-temperature brittleness, recrystallization brittleness, and other shortcomings due to the adjustment of the composition and organizational structure, such as the addition of alloying elements, adjusting the phase ratio, the use of heat treatment and deformation strengthening, etc. Its performance can be improved to meet the requirements for use in different fields. At present, the main production method of tungsten alloy is powder metallurgy. The use of a rolling open billet rotary forging-stretching process can improve production efficiency and product quality, but in actual production, due to the combined effects of various factors, such as elastic deformation of rolling elements, plastic deformation of the rolled material, etc., the mechanical properties of tungsten plates and bars are often difficult to control effectively, seriously affecting rolling stability and production efficiency. For this reason, researchers have conducted extensive and deep research and optimization on the rolling process of tungsten alloys, including establishing mathematical models, performing numerical simulations, optimizing process parameters, etc., providing important references for the rolling and forming of tungsten alloys. Meanwhile, the material properties are greatly influenced by the microstructure, and the evolution of the microstructure can be well quantified by some advanced characterization techniques, such as SEM, TEM, EBSD, etc., so that certain properties of tungsten can be obtained by controlling the texture evolution. In conclusion, this paper comprehensively summarizes the research progress of tungsten alloy roll forming and provides an important reference for further improving the processing performance and production efficiency of tungsten alloy.

Multimodal laser opto-ultrasonic spectroscopy (LOUS) Approach to investigate the impact of elemental composition on the engineering properties of high-density tungsten alloys'

The impact of elemental composition on the engineering properties of high-density tungsten alloy is crucial, particularly in relation to grain size, hardness, elastic modulus, and surface degradation. This study introduces a new multimodal laser opto-ultrasonic spectroscopy (LOUS) technique, which simultaneously integrates the benefits of laser-induced breakdown spectroscopy (LIBS) and laser ultrasonic testing to evaluate the engineering properties of tungsten alloys. The findings indicate that the increasing tungsten concentration significantly enhances the samples' hardness, grain size and elastic modulus. The composition of elements and hardness were assessed using a calibration curve derived from the emission intensity ratio (W-II/W-I) and plasma electron temperature (Te) in optical emission. The correlation results of (W-II/W-I) and Te showed significant enhancement with the increase of hardness with a regression coefficient (R2 ≥ 0.996), validating the Saha-Eggert relation and underscoring model effectiveness. Additionally, the correlation of the laser ultrasonic testing parameters (attenuation coefficient and velocities) in assessing grain size and elastic modulus showed good reliability (R2≥0.993) when compared to the results obtained from conventional optical microscopy and tensile testing. The results underscore the accuracy and predictive ability of the LOUS method for in-situ characterization.

Negative effect of lanthanum tungstate on the mechanical properties of W-La2O3 alloys

With the rapid development of the photovoltaic industry, tungsten alloys have been selected to replace the high‑carbon steel to fabricate the busbars for diamond wire saws due to their superior mechanical properties, and the La2O3 doped tungsten alloy has been widely used. However, the yield of eligible W alloy wires is not very high due to serious wire breakage problems during the production process, especially in the solid-liquid mixing route. To discover the possible reason, the commonly produced lanthanum tungstate (La30W17O96) in the solid-liquid mixing route has been systematically studied in the work, and its possible influence on the mechanical properties is also explored. It is found that the La30W17O96 leads to the formation of brittle second phases at grain boundaries (GBs), which weakens the intergranular bonding, resulting in a significant decrease in the compressive strength of tungsten alloys, manifested as intergranular fracture. Transmission electron microscopy (TEM) analysis reveals that these second phases are consisted of polycrystalline La6W2O15, La2W3O12 and amorphous states, and the La30W17O96 can decompose into a more stable structure during sintering. This work highlights the destructive effect of La30W17O96 on the intrinsic properties of tungsten alloys and provides a new perspective for solving the problem of tungsten wire breakage.

Radiation Effects in Tungsten and Tungsten-Copper Alloys Treated with Compression Plasma Flows and Irradiated with He Ions.

The paper presents the results of studying the structure and phase state of tungsten and tungsten-copper alloy after pulsed action of compression plasma flows and irradiation with helium ions. The compression plasma flows were used to modify the surface layer of tungsten, as well as to create an alloy based on tungsten and copper. Using scanning electron microscopy and X-ray structural analysis, the formation of radiation defects on the tungsten surface was detected in the form of local areas of exfoliation and destruction, which begin to form at helium ion irradiation doses of 2 × 1017 cm-2. It is shown that preliminary plasma treatment of the surface in the melting mode leads to the complete disappearance of surface radiation defects up to a dose of 2 × 1017 cm-2, which may be associated with the formation of a fine-crystalline grain structure, the intergranular boundaries of which serve as effective sinks for primary radiation defects.

Formation mechanism of Hf-based ceramic particles in tungsten alloys

Abstract To meet the requirements of high strength of tungsten (W) based alloys at high temperature applied in the aerospace field, the preparation and formation of Hf-related ceramic particles in W were studied. It is found that the HfO2 phase with a size of about 500 nm was observed at the grain boundary in both W-0.26 wt.% HfC and W-0.25 wt.% HfH2-0.125 wt.% C systems. Further study of phase stability and thermodynamic properties of Hf(W)-O(C) compounds reveals that the HfO2 phase possesses the most stability of all the Hf-related compounds, and the oxidation of Hf is preferred to the carbonization. It is predicted that more stability of W base metal, higher temperature, and higher carbon concentration can reduce the formation of HfO2 while promoting the formation of the HfC particle phase.

An investigation of the microstructure and properties of rolled W-Al2O3 alloy

Pure tungsten and tungsten alloys have been widely used in metallurgy, energy, chemical industry, aerospace, national defense, electronics and other fields. However, there are inevitably some problems in the use of the process, such as high deformation resistance in the forming process prone to crack and fracture, coarse grain and low bending strength problems. Al2O3 particles were added to improve the comprehensive properties of tungsten alloys. In this paper, the W-0.2 wt%Al2O3 tungsten alloy sheets with different thicknesses of 3 mm, 2 mm, and 1 mm were prepared by induction sintering combined with hot rolling. For comparison, the pure tungsten sheet with a thickness of 3 mm was fabricated by the same preparation process. Comparative assessments were made on the microstructure, hardness, and three-point bending properties across types of three thicknesses of W-Al2O3 sheets and pure tungsten sheet with a thickness of 3 mm. The outcomes demonstrate that the microstructure and properties of the tungsten alloy vary considerably depending on the applied rolling degree, which exerts a profound impact on the grain size, morphology, and distribution within the tungsten alloy matrix. Furthermore, the tungsten alloy consistently exhibits significant enhancements over pure tungsten. Characterization of the rolled tungsten alloy revealed that the incorporation of alumina contributes to a reduction in shear band formation and an improvement in texture strength, thereby substantiating its positive impact on the overall mechanical properties of the alloy.

Trailblazing multi-material structure: Niobium alloy to tungsten–copper composite using wire-arc additive manufacturing

Integrating tungsten and niobium alloys into a single component offers synergistic benefits for fusion reactor applications. Additive manufacturing, particularly for components with complex geometries, further amplifies these advantages. This study examines the fabricability of a multi-material structure composed of a W–Cu composite and an Nb–Zr alloy using wire-arc additive manufacturing. The resulting W–Cu/Nb–Zr structure was free from significant defects like porosity or cracks, though the formation of hard intermetallic compounds was observed. Numerical analysis indicated considerable residual stress accumulation at the interface. During tensile testing, fractures occurred in the W–Cu composite near the interface, with the specimens exhibiting an ultimate tensile strength of 218 ± 3 MPa and an elongation of 5.7 ± 1 %.