With mentoring support of F4E experts, and leveraging its expertise in friction stir welding (FSW), TWI has developed CoreFlow®, a breakthrough process for creating internal cooling channels within copper and CuCrZr alloys. Originally developed for aluminium, CoreFlow® has now been successfully adapted to meet the demanding structural and thermal requirements of nuclear fusion environments.

This patented, single-step sub-surface machining technology enables the production of optimised cooling channels without compromising the material’s integrity—an essential feature for manufacturing Plasma-Facing Components (PFCs) and other critical fusion reactor systems.

• Proven Performance: Developed and validated for nuclear fusion-grade materials, including copper and CuCrZr, meeting the highest standards for thermal management and structural stability.
• Fusion-Ready: Supports the design and manufacturing of PFCs for Tokamak reactors, enhancing heat dissipation while preserving material properties in high-radiation and high-heat flux conditions.
• Design Flexibility: Allows intricate and customisable internal geometries tailored to specific cooling needs—ideal for advanced component engineering and performance optimisation.
• Cross-Sector Potential: Adaptable to sectors such as aerospace, electric mobility, and industrial energy systems, where efficient and scalable thermal solutions are critical.