Diffusion bonding of niobium alloys with tungsten and a molybdenum alloy for high-energy particle target applications

Particle-producing targets in high-energy research facilities are often made from refractory metals, and they typically require dedicated cooling systems due to the challenging thermomechanical conditions they experience. However, direct contact of water with target blocks can induce erosion, corrosion, and embrittlement, especially of tungsten (W). One approach to overcoming this problem is cladding the blocks with tantalum (Ta). Unfortunately, Ta generates high decay heat when irradiated, raising safety concerns in the event of a loss-of-cooling accident. This study explored the capacity of niobium (Nb) and its alloys to form diffusion bonds with W and TZM (a molybdenum alloy with titanium and zirconium). This is because the Beam Dump Facility (BDF), a planned new fixed-target installation in CERN’s North Area, uses these target materials. The bonding quality of pure Nb, Nb1Zr, and C103 (a Nb alloy with 10 wt% hafnium and 1 wt% titanium) with TZM and W obtained using hot isostatic pressing (HIP) was evaluated. The effects of different HIP temperatures and the introduction of a Ta interlayer were examined. Optical microscopy indicated promising bonding interfaces, which were further characterized using tensile tests, thermal-diffusivity measurements and metallurgical inspections. Their performance under high-energy beam impact was validated using thermomechanical simulations. C103 exhibited higher interface strengths and safety factors than Ta2.5 W, positioning it as a potential alternative cladding material for the BDF production target. The findings highlight the viability of Nb-based materials, particularly C103, for improving operational safety and efficiency in fixed-target physics experiments; however, considerations regarding the long half-life of 94Nb require further attention.