The thermo-mechanical behaviour of W-Cu metal matrix composites for fusion heat sink applications: The influence of the Cu content

Abstract Copper and its alloys are used as heat sink materials for next generation fusion devices and will be joined to tungsten as an armour material. However, the joint of W and Cu experiences high thermal stresses when exposed to high heat loads so an interlayer material could effectively ensure the lifetime of the component by reducing the thermal mismatch. Many researchers have published results on the production of W-Cu composites aiming attention at its thermal conductivity; nevertheless, the mechanical performance of these composites remains poor. This paper reports the characterization of the thermo-mechanical behaviour of W-Cu composites produced via a liquid Cu melt infiltration of porous W preform. This technique was applied to produce composites with 15, 30 and 40 wt% Cu. The microstructure, thermal properties, and mechanical performance were investigated and measured from RT to 800 °C. The results demonstrated that high densification and superior mechanical properties can indeed be achieved via this manufacturing route. The mechanical properties (elastic modulus, fracture toughness, and strength) of the composites show a certain dependency on the Cu content; fracture mode shifts from the dominantly brittle fracture of W particles with constrained deformation of the Cu phase at low Cu content to the predominance of the ductile fracture of Cu when its ratio is higher. Though strong degradation is observed at 800 °C, the mechanical properties at operational temperatures, i.e. below 350 °C, remain rather high—even better than W/Cu materials reported previously. In addition, we demonstrated that the elastic modulus, and therefore the coefficient of thermal expansion, can be tailored via control of the W skeleton's porosity. As a result, the W-Cu composites presented here would successfully drive away heat produced in the fusion chamber avoiding the mismatch between materials while contributing to the structural support of the system.