Nuclear fusion, a process mirroring the energy production of the sun and stars, holds promise for generating electricity on Earth without carbon emissions or long-lasting nuclear waste. The success of this technology hinges on developing materials that can endure extreme temperatures, mechanical stress, and neutron damage. Researchers are focusing on novel metal alloys and ceramic composites to advance fusion reactor designs.
David Sprouster, an assistant professor at Stony Brook University’s Department of Materials Science and Chemical Engineering, is leading research projects aimed at overcoming the challenges associated with new materials for fusion energy. “My research is really about stress testing these different materials to see how we can improve their function when exposed to different combinations of extremes,” said Sprouster.
Sprouster’s team has secured three multi-million dollar grants for their work on fusion energy materials, including two from the Department of Energy’s Office of Fusion Energy Sciences Fusion Innovation Research Engine (FIRE) Collaboratives.
In one study, Sprouster’s group compared two steels fabricated by traditional casting and direct current sintering. This process uses heat and pressure to rapidly convert powders into solid material, allowing complex structures needed in fusion chambers. Both methods showed good resistance to deformation under heat and stress over time — a phenomenon known as “creep.” Sprouster explained, “Creep is a very slow process… but we have had success in designing the least ‘creepy’ materials.”
The study found that while both materials resisted creep well, higher temperatures made dislocations move more easily, increasing susceptibility to deformation. This knowledge helps predict steel performance in high-temperature conditions like those in fusion reactors.
In another study, Sprouster’s team used direct current sintering to create steel composites with hafnium hydride for neutron shielding in advanced nuclear reactors. “The hydrogen is there to stop the neutrons,” said Sprouster. The research revealed that heating caused hafnium hydride to release hydrogen slowly at higher temperatures than expected in reactor applications.
These studies aim to develop safer and more durable materials for future fusion reactors. Lance Snead, a research professor at Stony Brook University, noted that private investment now dominates funding in this field due to its potential as a near-term electricity source.
“Fusion is very exciting right now,” said Sprouster. He highlighted strong collaborations among universities, national labs, and industry focused on solving engineering problems through material science solutions.
Future work at Stony Brook University’s Department of Materials Science and Chemical Engineering will continue developing advanced materials capable of withstanding the extreme environments inherent in fusion technology.
