Cold Spray metal powder deposition with 9%Cr-steel applied for the HCPB First Wall fabrication: proof of concept and options for ODS steel processing

At the KIT a hybrid manufacturing concept for nuclear fusion First Walls is developed combining aspects of conventional and Additive Manufacturing (AM) technologies. The state of the art for ITER does not cover all specifications of a DEMO relevant First Wall. Thus, additional R&D-work has been initiated in terms of manufacturing. The AM technology basis used in the presented process combination is Cold Spray metal powder deposition applied in alternation with machining including the feature of filling grooves temporarily with a water-soluble granulate for creation of closed channels and cavities. Thus, the technology provides the option to manufacture shells with a thin gas tight membrane on top of previously machined structures. This membrane is used as pressure seal and makes the joining of shells by Hot Isostatic Pressing (HIP) into one monolithic body possible. This paper describes the manufacturing process and recalls differences and common aspects with regard to conventional concepts of First Wall manufacturing. The achievement of Technology Readiness Level TRL 3 by mechanical qualification and comparison of the results to other HIP joint experiments is also demonstrated. Finally, an outlook is given concerning integration options of the technology into manufacturing of shells with cooling channel structures using Oxide Dispersion Strengthened (ODS) materials.