Through work conducted within the EUROfusion programme, RINA-CSM and ENEA have demonstrated the feasibility of recycling irradiated steels from future DEMO fusion reactors by converting them into metal powders and reusing them through additive manufacturing. The approach addresses the environmental and economic challenges of radioactive waste by transforming activated steels into valuable feedstock, while minimising residual waste.

The method combines advanced metallurgical and AM processes. Steels such as EUROFER and AISI 316L(N) undergo Vacuum Induction Melting, followed by Vacuum Oxygen Decarburisation, which enables efficient removal of Carbon-14. A Vacuum Induction Gas Atomisation process then produces powders tailored for Selective Laser Melting. Trials confirmed powder quality suitable for AM, with preliminary SLM specimens achieving 99.5% density and no macro-defects.

The process, though designed for fusion, could be used in non-fusion sectors:

• Nuclear fission: Recycling activated steels from reactor decommissioning into new components.
• Big science facilities: Managing activated materials from particle accelerators or similar infrastructures.
• Defence and aerospace: Reutilisation of radiologically exposed parts from ships or satellites.
• Heavy industry: Application to toxic or complex metallic waste streams in mining or petrochemicals.

In each case, the approach offers a sustainable alternative to conventional disposal or immobilisation, transforming liabilities into reusable material.