The reactive spark plasma sintering (R-SPS) method was compared in this work with the two-step SHS–SPS route, based on the combination of the self-propagating high-temperature synthesis (SHS) with the SPS process, for the fabrication of dense (Hf_0.2Mo_0.2Ti_0.2Ta_0.2Nb_0.2)B₂–SiC and (Hf_0.2Mo_0.2Ti_0.2Ta_0.2Zr_0.2)B₂–SiC ceramics. A multiphase and inhomogeneous product, containing various borides, was obtained at 2000 °C/20 min by R-SPS from transition metals, B₄C, and Si. In contrast, if the same precursors were first reacted by SHS and then processed by SPS under the optimized condition of 1800 °C/20 min, the desired ceramics were successfully attained. The resulting sintered samples possessed relative densities above 97% and displayed uniform microstructures with residual oxide content <2.4 wt.%. The presence of SiC made the sintering temperature milder, i.e., 150 °C below that needed by the corresponding additive-free system. The fracture toughness was also markedly improved, particularly when considering the Nb-containing system processed at 1800 °C/20 min, whereas the fracture toughness progressively decreased (from 7.35 to 5.36 MPa m^1/2) as the SPS conditions became more severe. SiC addition was found to inhibit the volatilization of metal oxides like MoO₃ formed during oxidation experiments, thus avoiding mass loss in the ceramics. The benefits above also likely took advantage of the fact that the two composite constituents were synthesized in parallel, according to the SHS–SPS approach, rather than being produced separately and combined subsequently, so that strong interfaces between them were formed.

The aim of the research campaign was to simulate in vitro the typical conditions for the corrosion in biofluid of a femoral bone implant manufactured with AZ31 alloy. The samples were immersed in biofluid (alpha-MEM) for time intervals of up to 56 days. For each immersion time, the chemical compositions and morphologies of the samples were studied with SEM, EDX, XRD, Raman spectroscopy, and XPS. The weight losses of the samples caused by corrosion were also measured. The results highlighted the formation of calcium phosphate crystals on the surface of the samples. This type of coating is well-known for its excellent corrosion resistance and for its ability to accelerate tissue regeneration. The deceleration of the corrosion process, observed after 28 days of immersion in biofluid, confirms the anti-corrosive effect of the coating that was spontaneously formed during the immersion tests.

The selection of a suitable plasma-facing material (PFM) that must protect the divertor, cooling systems, and structural components is an important challenge in the design of advanced fusion reactors and requires careful consideration. Material degradation due to melting and evaporation may lead to plasma contamination, which must be strictly avoided. Among the candidate materials, tungsten (W) is the most promising because of its thermo-mechanical and physical properties, which allow it to endure repeated exposure to extremely harsh conditions within the reactor. The plasma spraying (PS) technique is gaining increasing interest for the deposition of tungsten (W) coatings to protect heat sink materials, due to its relatively low cost, high deposition rates, and capability to coat complex-shaped surfaces and fix damaged coatings in situ. This review aims to provide a systematic assessment of tungsten (W) coatings produced by PS techniques, evaluating their suitability as PFMs. It discusses W-based materials, plasma spraying technologies, the role of the interface in joining W coating and metallic substrates such as copper alloys and steels, and the main issues related to coating surface erosion under steady-state and transient heat loads associated with advanced fusion reactor operation modes and off-normal events. Quantitative data available in the literature, such as porosity, oxygen content, thermal conductivity of the coatings, residual stresses accumulated in the coating–substrate interface, surface temperature, and material loss following heat load events, were summarized and compared to bulk W ones. The results demonstrate that, following optimization of the fabrication process, PS-W coatings exhibit excellent performance. In addition, previously mentioned advantages of PS technology make PS-W coatings an attractive alternative for PFM fabrication.

The construction and operation of the first generation of magnetically controlled nuclear fusion power plants require the development of proper physics and the engineering bases. The analysis of data, recently collected by the actual largest and most important tokamak in the world JET, that has successfully completed his second deuterium and tritium campaign in 2021 (DTE2) with a full ITER like wall main chamber, has provided an important consolidation of the ITER physics basis. Thermonuclear plasmas are highly nonlinear systems characterized by the need of numerous diagnostics to measure physical quantities to guide, through proper control schemes, external actuators. Both modelling and machine learning approaches are required to maximize the physical understanding of plasma dynamics and at the same time, engineering challenges have to be faced. Fusion experiments are indeed extremely hostile environments for plasma facing materials (PFM) and plasma-facing components (PFC), both in terms of neutron, thermal loads and mechanical stresses that the components have to face during either steady operation or off-normal events. Efforts are therefore spent by the community to reach the ultimate goal ahead: turning on the first nuclear fusion power plant, DEMO, by 2050. This editorial is dedicated at reviewing some aspects touched in recent studies developed in this dynamic, challenging project, collected by the special issue titled “New Challenges in Nuclear Fusion Reactors: From Data Analysis to Materials and Manufacturing”.

In this work a W coating was deposited through PS in Ar-H₂ atmosphere on a substrate of CuCrZr with an interlayer consisting of gradually changing fractions of Cu and W. The W coating and the interlayer showed good adhesion and no cracks were observed. The hardness of W and Cu along the interlayer was determined by nano-indentation tests and the results showed that a hardness gradient does exist in both the metals. Microstructural examinations suggest that the hardness gradient depends on the texture, which exhibits significant differences along the interlayer: multiplication and movement of dislocations, and localized plasticity under the indenting tip are strongly affected by grain orientation.