GalvanoFusion project: Electrochemical process for tungsten coatings
A research alliance between the Max Planck Institute for Plasma Physics (IPP) and the specialty electrolyte manufacturer IoLiTec, led by Fraunhofer IPA, is developing a globally innovative technology for the electrochemical deposition of pure tungsten layers.
The project, which will run until the end of 2028, aims to protect the inner walls of future fusion reactors - known as the first wall - with tungsten coatings. Due to its heat resistance and robustness, tungsten is the material of choice for plasma-exposed surfaces that have to withstand loads of up to 10 megawatts per square meter. As a so-called refractory metal with a melting point of over 3000 degrees Celsius, tungsten can withstand even extreme thermal loads. But the material is rare: With only one millionth of the earth's crust, it is considered a conflict raw material and is extremely difficult to process mechanically. Manufacturing entire components from tungsten is therefore neither economical nor practical. The solution: a thin layer of tungsten on a carrier material that is easier to handle.
Tungsten as a key material for fusion reactors
The scientific challenge lies in the nature of the metal itself: Classic galvanic processes, as used in industry, fail due to a physical hurdle: Tungsten has a very low hydrogen overvoltage. Therefore, no metal is deposited in aqueous electrolytes, only hydrogen is produced. The research alliance is therefore breaking new scientific ground with anhydrous electrolytes based on ionic liquids and organic solvents. "There is no other process in the world for the electrochemical deposition of pure tungsten - neither industrially nor in the laboratory," emphasizes project manager Andreas Waibel from the Fraunhofer Institute for Manufacturing Engineering and Automation IPA.
Electrochemical deposition as a technological hurdle
The three partners contribute complementary expertise: IPP defines the requirements for the coatings and carries out application-related tests under fusion-relevant conditions. Fraunhofer IPA develops the entire coating process with the aim of later industrial scaling. IoLiTec contributes the know-how for formulating the special ionic liquids. The project "GalvanoFusion - Electrochemical deposition of tungsten layers for fusion reactors from non-aqueous electrolytes" is funded by the Federal Ministry of Research, Technology and Space (BMFTR) as part of the Fusion 2040 - Research on the way to the fusion power plant funding program under the funding code 13F1034A with a term from January 1, 2026 to December 31, 2028.