Advanced Manufacturing of High-Entropy Alloys as Cost-Effective Plasma Facing Components for Fusion Power Generation

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OPEN 2021
Los Alamos, New Mexico
Project Term:
09/01/2022 - 12/31/2099

Critical Need:

High-performance structural and plasma-facing components (PFCs) are critical for the future success of fusion power plants (FPPs). PFCs must maintain stability in thermomechanical properties and irradiation resistance under the extreme conditions in fusion reactors. This challenge in fusion reactor design must be met to proceed on the path toward fusion power generation. The primary PFC candidate material is tungsten (W) due to its fusion-favorable properties (high melting point, good thermal properties, and low tritium retention). These features critically degrade during exposure to plasma and neutron fluxes, however, due to severe radiation-induced microstructural modifications in the W components.

Project Innovation + Advantages:

Los Alamos National Laboratory (LANL) aims to use additive manufacturing techniques to develop novel W-based high-entropy alloys (HEAs) with compositions and microstructures optimized for ideal performance in PFCs. Atomistic simulations and high-throughput additive processing characterizations will guide manufacturing of these materials. LANL’s project will investigate the HEA PFC performance under fusion relevant conditions, characterizing irradiation resistance, thermal stability, thermoelastic properties, and thermomechanical properties. Scale-up will entail the use of laser powder-bed fusion additive manufacturing to fabricate more complex parts. This project’s findings will be invaluable for the initial down selection of novel PFC candidate materials in various fusion reactor designs.

Potential Impact:

Reliable PFCs will reduce maintenance downtime in fusion power plants and increase first-wall reliability, making fusion power generation more cost-effective, economically predictable, and commercially attractive.


If successful, this project will expand commercial fusion energy as it will advance the technology readiness level of HEA PFCs to optimize fusion power plant performance.


This project aims to develop the first materials capable of actually serving adequately as FPP PFCs, enabling a groundbreaking and sustainable energy source.


If successful, this project will reduce all cost (including maintenance) associated with PFCs from $200MM/year to lower than $20MM/year.


ARPA-E Program Director:
Dr. Robert Ledoux
Project Contact:
Osman El Atwani
Press and General Inquiries Email:
Project Contact Email:


University of Wisconsin

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