Recent Development of Oxide Dispersion-Strengthened Copper Alloys for Application in Nuclear Fusion

The performance of conventional precipitation-strengthened copper alloys drastically degrades at temperatures exceeding 500 °C, hindering their application under extreme conditions like those in nuclear fusion reactors. Oxide dispersion–strengthened copper (ODS–Cu) alloy surmounts these constraints by incorporating thermally stable, nanoscale oxide dispersoids that simultaneously confer strengthening, microstructural stabilization, and enhanced irradiation tolerance, while preserving high thermal conductivity. This review comprehensively examines the state of the art in ODS–Cu alloy from a “processing–microstructure–property” perspective. We critically assess established and emerging fabrication routes, including internal oxidation, mechanical alloying, wet chemical synthesis, reactive spray deposition, and additive manufacturing, to evaluate their efficacy in achieving uniform dispersions of coherent/semi-coherent nano-oxides at engineering-relevant scales. The underlying strengthening mechanisms and performance trade-offs are quantitatively analyzed. The review also outlines strategies for joining and manufacturing complex components, highlights key gaps in metrology and reproducibility, and proposes a roadmap for research and standardization to accelerate industrial deployment in plasma-facing components.