Functionally graded tungsten/steel composites are attractive to be used as an interlayer to join tungsten (W) and steel for the first wall of future fusion reactor to reduce the thermally induced stresses arising from the different coefficient of thermal expansion (CTE) of W and steel. W/steel composites, with three W contents: 25, 50 and 75 vol% W, will serve as individual sublayers of this functionally graded material. Therefore, the present work exploits an emerging sintering technique, field-assisted sintering technology, to produce these composites. Firstly, a systematic parameter study was conducted aiming to reduce the residual porosity to a minimum while keeping the formation of intermetallic phases at the W/steel interface at a low level. The optimized composites 25, 50 and 75 vol% W achieved a relative density of 99%, 99% and 96%, respectively. Secondly, mechanical tests at elevated temperatures reveal that these composites are ductile above 300 °C, which is the minimum operating temperature of the first wall. Lastly, the measured CTE, specific heat capacity and thermal conductivity were consistent with the theoretically expected values.

Material issues pose a significant challenge for the design of future fusion reactors. These issues require new advanced materials to be developed. W‐fiber‐reinforced W‐composite material (W _f/W) incorporates extrinsic toughening mechanisms increasing the resistance against failure and thus granting steps toward application in a future fusion reactor. W _f/W can be produced based on chemical vapor deposition or powder metallurgical routes. In this contribution, the efforts of upscaling the production of W _f/W will be reviewed based on recent results. In addition, the activities related to enabling large‐scale production for new fusion applications are being studied. Herein, two main achievements are to be highlighted. First, an upscaled production is established to produce flat tile samples for joining tests on copper and steel, and second, a new method of joining W _f/W on copper is established and tested under high heat‐flux conditions.