CuCrZr heat-sink irradiation performance reveals new challenges for thermonuclear fusion reactors
Commercial fusion energy requires materials that survive intense neutron bombardment whilst extracting extreme heat loads for conversion to electricity. The CuCrZr alloy, the leading heat-sink material for fusion reactors, derives its strength from a fine dispersion of nano-precipitates formed during prime-ageing heat-treatment. Whether this precipitation-hardening strategy can withstand fusion-relevant irradiation remains untested. Here we show, combining in situ transmission electron microscopy under heavy-ion irradiation and He implantation with thermodynamic and transmutation modelling, that the hardening precipitates dissolve under two opposing kinetic regimes: ballistic dissolution dominates at low temperatures, whilst dissolution and re-precipitation dominate at high temperatures. Although the accelerated dose rates inherent to ion irradiation shift the balance between ballistic mixing and thermal back-diffusion relative to reactor conditions, precipitate degradation at both kinetic extremes indicates that the prime-aged microstructure is unlikely to remain unaltered under prolonged neutron exposure. He bubbles and Kr-rich voids nucleate once vacancies become mobile, and transmutation over five service years irreversibly redirects the alloy chemistry towards Ni-Zr intermetallics. These three independent mechanisms converge to challenge the strategy on which CuCrZr performance depends, suggesting that the long-term performance of age-hardenable Cu-based heat-sink alloys in fusion reactors warrants further assessment. Our findings reveal a new materials challenge for fusion reactor design and commercialisation: the need for new Cu-based heat-sink alloys able to retain engineered strength whilst their chemistry is irreversibly rewritten - thermodynamically and ballistically - by the fusion neutron spectrum.