Self-powered brazing of Ti-6Al-4V was performed using Ni/Al reactive multilayer films (RMFs) as self-propagated heat resources. BAlSi-4 was first coated on Ti-6Al-4V by plasma welding, then alternating layers of Ni and Al were successfully deposited on BAlSi-4 up to 32.9 μm thick with e-beam deposition. The joint microstructure was investigated and the AlNi and Ni₅Al₃ phases were identified in the RMF. The cause for the two phases was determined to be differences in the diffusivity of Ni and Al, ultrafast brazing time, and faster cooling at the interface between brazing filler metal and the RMF. The maximum temperature of 683 °C was reached in the brazed joint, with a total RMF thickness of 135 μm, which is more than sufficient to melt the BAlSi-4 brazing material. The maximum bonding strength obtained was 10.6 MPa, with a self-power brazing procedure conducted in a minute. It is possible to further improve the bonding strength by using more ductile RMFs and/or modifying the bonding interface configuration.

There are currently few viable diagnostic techniques for in situ measurement of plasma facing component erosion. Digital holography is intended to fill this gap. Progress on the development of single and dual CO₂ laser digital holography diagnostics for in situ plasma facing component erosion is discussed. The dual laser mode’s synthetic wavelength allows the measurable range to be expanded by a factor of ∼400 compared to single laser digital holography. This allows the diagnostic to measure surface height changes of up to 4.5 μm in single laser mode and up to 2 mm in dual laser mode. Results include ex situ measurements of plasma eroded targets and also dynamic measurements of nm and μm scale motion of a target mounted on a precision translation stage. Dynamic measurements have successfully been made with the system operating in both single and dual laser modes, from ∼50 nm to ∼4 μm in single laser mode and up to ∼400 μm in dual laser mode (limited only by the stage speed and camera acquisition duration). These results demonstrate the feasibility of using digital holography to characterize plasma facing component erosion dynamically, i.e., during plasma exposure. Results of proof-of-principle in situ digital holographic measurements of targets exposed to an electrothermal arc plasma source are presented.

A digital holography device is currently undergoing development at the Oak Ridge National Laboratory for the purpose of measuring surface topography, with the goal of deployment as a real-time plasma-facing component diagnostic for the study of materials that could be utilized in a nuclear fusion device. The holography system utilizes one or two lasers depending on the scale of surface features under measurement. Measurements of surface roughness were performed in a single-laser mode and compared with the data from profilometry, with a linear correlation of increased holographic measurement fidelity as surfaces became smoother. Characterization of the dual-laser operating mode has been performed via surface measurement of stainless steel targets with ``stair-step'' features in various sizes. Results demonstrated that surface features with known sizes as small as 25.4 μm could be resolved. Measurements were within ~55 μm or less deviation from the actual sizes, and measurement accuracy was improved as feature size was increased, corresponding to the effect of noise becoming less pronounced. A target exposed to plasma generated by an electrothermal (ET) arc source was analyzed with flat-field correction and averaging of sequential image frames to demonstrate the improved measurement quality in preparation for future use of holography on ET arc-exposed targets.

Digital holography has been proposed to fulfill a need for an imaging diagnostic capable of in situ monitoring of surface erosion caused by plasma–material interaction in nuclear fusion devices. A digital holography diagnostic for 3D surface erosion measurement has been developed at Oak Ridge National Laboratory with the goal of deployment on a plasma device. A proof-of-concept in situ demonstration is planned which would involve measurement of plasma erosion on targets exposed to an electrothermal arc source. This work presents the results of an ex situ characterization of the capability and limitations of holographic imaging of targets exposed to the arc source. Targets were designed to provide a fiducial for comparison of deformed and unaffected areas. The results indicated that the average net erosion was ∼150 nm/plasma exposure, which is expected to be within the diagnostic’s measurement capacity. Surface roughness averages determined by holographic image analysis showed good agreement with measurements taken with a profilometer. The limit of the holography diagnostic’s x–y spatial resolution was characterized by comparison with scanning electron microscope imaging.