Formation and Design of AM-processed Fe-Al alloys with self-forming Hydrogen Permeation Barriers for the harshest of environments

The primary objective of the project is the design and realisation of high-strength density-graded high-temperature oxidation-resistant Fe-Al alloy, capable of self-passivation with hydrogen permeation barrier scale. With controlled oxidation behaviour at high temperatures and the ability to mitigate corrosion and hydrogen embrittlement, such materials can be fine-tuned for operation in challenging environments up to 1000 °C. Here, we combine several peculiarities of the Fe-Al system into a self-passivated layered composite, capable of solving some of the current material-related challenges preventing the development of very high-temperature engineering applications, including in complex energy systems such as fusion and hydrogen economy devices and storage. Along the path to successful realisation, several critical challenges must be resolved, and for each, we propose a unique solution. The workflow is composed of four interconnected parts: [1] strategies for improvement of Fe-Al structural properties for applications at high temperatures and their implementation in AM-processing of Fe-Al alloys, and their influence on the [2] formation and phase transformation of protective superficial thin oxide alumina-rich scales, [3] testing and exploration of such scales as a hydrogen permeation barriers and [4] implementation of Fe-Al alloys as plasma-facing fusion-relevant structural materials with the ability of self-forming hydrogen permeation barriers.