journal article·2020-12Open access

Mechanical and chemical properties of PVD and cold spray Cr-coatings on Zircaloy-4

Rajnikant V. Umretiya, Barret Elward, Donghwi Lee, Mark Anderson, Raul B. Rebak, Jessika V. Rojas

Abstract

Abstract Accident-tolerant fuel (ATF) cladding materials aim to improve fuel reliability and safety during accident scenarios in water-cooled reactors. These ATF cladding should also perform comparable or better than the current zirconium alloy cladding under reactor normal operating conditions. Surface-modified Zircaloy-4 was produced by depositing a protective coating of chromium by two different coating techniques, Physical Vapor Deposition (PVD) and Cold Spray (CS). The coating thickness, structure, composition, and mechanical properties of the coated Zircaloy were assessed with advanced materials characterization techniques. Results showed a strengthening effect of the Cr-coating, along with ∼83% higher hardness compared to that of the Zircaloy-4 substrate. Surface topography and surface chemistry of the Cr-coated Zircaloy-4 were assessed with contact profilometry, atomic force microscopy, contact angle goniometry, and X-ray photoelectron spectroscopy. Deposited Cr-coating significantly improved surface wettability compared to the substrate Zircaloy-4. The formation of surface oxides on the coatings by prolonged exposure to ambient air showed a further increase in the hydrophobic behavior. Surface parameters and surface chemistry after flow boiling critical heat flux tests, conducted at atmospheric pressure, evidenced a slight increase in surface roughness with notable changes in wettability associated with the formation of surface oxides.
Source: openaire · Quality: candidate unverified · Source record ↗

Research context

OpenAlex topics: Nuclear Materials and Properties · High-Temperature Coating Behaviors · Fusion materials and technologies

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

References (100+)

Show source-provided references
1. Development of advanced accident-tolerant fuels for commercial LWRs
2. Accident tolerant fuel cladding development: promise, status, and challenges10.1016/j.jnucmat.2017.12.043 ↗
3. Overview of the U.S. DOE accident tolerant fuel development program
4. 2012
5. Current status of materials development of nuclear fuel cladding tubes for light water reactors10.1016/j.nucengdes.2017.02.031 ↗
6. Evolutionary developments of advanced PWR nuclear fuels and cladding materials10.1016/j.nucengdes.2013.04.013 ↗
7. Accident tolerant fuels for LWRs: a perspective10.1016/j.jnucmat.2013.12.005 ↗
8. F. Goldner, Development strategy for advanced LWR fuels with enhanced accident tolerance, enhanced accident tolerant LWR fuels national metrics workshop, Germantown, MD, 2012.
9. T. Fuel, F.O.R. Light, W. Reactor, Tolerant Fuel For Light Water Reactor Lwrs, (n.d)1–11.
10. Accident tolerant nuclear fuels and cladding materials10.1007/s11837-017-2701-3 ↗
11. Advanced oxidation-resistant iron-based alloys for LWR fuel cladding10.1016/j.jnucmat.2013.06.041 ↗
12. Steam oxidation behavior of fecral cladding
13. Oxidation of fuel cladding candidate materials in steam environments at high temperature and pressure10.1016/j.jnucmat.2012.05.007 ↗
14. Material selection for accident tolerant fuel cladding
15. Selection of fuel cladding material for nuclear fission reactors10.1016/j.engfailanal.2011.06.010 ↗
16. Alloy selection for accident tolerant fuel cladding in commercial light water reactors
17. Development status of accident-tolerant fuel for light water reactors in Korea10.1016/j.net.2015.11.011 ↗
18. High temperature steam-oxidation behavior of arc ion plated Cr coatings for accident tolerant fuel claddings10.1016/j.surfcoat.2015.09.022 ↗
19. Application of coating technology on zirconium-based alloy to decrease high-temperature oxidation
20. AREVA NP's enhanced accident-tolerant fuel developments: focus on Cr-coated M5 cladding10.1016/j.net.2017.12.004 ↗
21. Behavior under LOCA conditions of enhanced accident tolerant chromium coated Zircaloy-4 claddings
22. On-going studies at CEA on chromium coated zirconium based nuclear fuel claddings for enhanced Accident Tolerant LWRs Fuel
23. Improving accident tolerance of nuclear fuel with coated Mo-alloy cladding10.1016/j.net.2015.12.003 ↗
24. Radiation tolerance of neutron-irradiated model Fe-Cr-Al alloys10.1016/j.jnucmat.2015.06.023 ↗
25. Characteristics of composite silicon carbide fuel cladding after irradiation under simulated PWR conditions10.13182/NT12-86 ↗
26. High-temperature tensile strength of near-stoichiometric SiC/SiC composites10.1016/S0022-3115(02)01049-8 ↗
27. Characterization of SiC-SiC composites for accident tolerant fuel cladding10.1016/j.jnucmat.2015.08.020 ↗
28. Enchanced high-temperature performances of SiC/SiC composites by high densification and crystalline structure10.1016/j.compscitech.2010.11.026 ↗
29. Mechanical properties of SiC composites neutron irradiated under light water reactor relevant temperature and dose conditions10.1016/j.jnucmat.2017.07.007 ↗
30. Development of surface modified Zr cladding by coating technology for ATF
31. High-temperature tests of silicon carbide composite cladding under GFR conditions10.1016/j.egypro.2017.08.116 ↗
32. SiC/Si thin film deposited on zircaloy to improved accident tolerant fuel cladding10.1016/j.tsf.2018.06.006 ↗
33. K.G. Field, M. Snead, Y. Yamamoto, B.A. Pint, K.A. Terrani, Materials properties of FeCrAl alloys for nuclear power production applications (2017), p. 39.10.2172/1474581 ↗
34. A comparative study on the wear behaviors of cladding candidates for accident-tolerant fuel10.1016/j.jnucmat.2015.05.017 ↗
35. Microstructure and high temperature mechanical properties of as-cast FeCrAl alloys10.1016/j.msea.2018.04.039 ↗
36. Development and property evaluation of nuclear grade wrought FeCrAl fuel cladding for light water reactors10.1016/j.jnucmat.2015.10.019 ↗
37. Neutronic analysis of candidate accident-tolerant cladding concepts in pressurized water reactors10.1016/j.anucene.2014.09.005 ↗
38. Mechanical properties of neutron-irradiated model and commercial FeCrAl alloys10.1016/j.jnucmat.2017.03.038 ↗
39. Microstructure and mechanical properties of FeCrAl alloys under heavy ion irradiations10.1016/j.jnucmat.2018.03.002 ↗
40. Utilizing FeCrAl oxidation resistance properties in water, air and steam for accident tolerant fuel cladding10.1149/08502.0003ecst ↗
41. Rebak RB (2017) Iron-chrome-aluminum alloy cladding for increasing safety in nuclear power plants. 34:. https://doi.org/10.1051/epjn/2017029.10.1051/epjn/2017029 ↗
42. Oxidation characteristics of two FeCrAl alloys in air and steam from 800°C to 1300°C10.1007/s11837-018-2979-9 ↗
43. Versatile oxide films protect FeCrAl alloys under normal operation and accident conditions in light water power reactors10.1007/s11837-017-2705-z ↗
44. Uniform corrosion of FeCrAl alloys in LWR coolant environments10.1016/j.jnucmat.2016.06.047 ↗
45. Behavior of an improved Zr fuel cladding with oxidation resistant coating under loss-of-coolant accident conditions10.1016/j.jnucmat.2016.10.021 ↗
46. A study of the oxidation of FeCrAl alloy in pressurized water and high-temperature steam environment10.1016/j.corsci.2015.02.027 ↗
47. (2019) Steam oxidation, burst and critical heat flux testing of commercial fecral cladding B. A. Pint, L. A. Baldesberger and K. A. Kane. 311–316.
48. Protective coatings on zirconium-based alloys as accident-Tolerant fuel (ATF) claddings10.1515/corrrev-2017-0010 ↗
49. Barrett K, Bragg-Sitton S, Galicki D (2012) Advanced LWR nuclear fuel cladding system development trade-off study. Idaho 83415 INL/EXT-12-27090 1–34. https://doi.org/10.2172/1057698.10.2172/1057698 ↗
50. Deposition, characterization and performance evaluation of ceramic coatings on metallic substrates for supercritical water-cooled reactors10.1016/j.surfcoat.2010.12.017 ↗
51. Vacuum-arc chromium-based coatings for protection of zirconium alloys from the high-temperature oxidation in air10.1016/j.jnucmat.2015.06.016 ↗
52. Out-of-pile performance of surface-modified Zr cladding for accident tolerant fuel in LWRs10.1016/j.jnucmat.2018.07.061 ↗
53. Application of coating technology on Zirconium-based alloy to decrease high-temperature oxidation
54. Adhesion property and high-temperature oxidation behavior of Cr-coated Zircaloy-4 cladding tube prepared by 3D laser coating10.1016/j.jnucmat.2015.06.030 ↗
55. Development of cold spray coatings for accident-tolerant fuel cladding in light water reactors10.1007/s11837-017-2643-9 ↗
56. Development of Cr cold spray – coated fuel cladding with enhanced accident tolerance10.1016/j.net.2017.12.011 ↗
57. Experimental investigation of cold-spray chromium cladding
58. Early studies on Cr-Coated Zircaloy-4 as enhanced accident tolerant nuclear fuel claddings for light water reactors10.1016/j.jnucmat.2019.02.018 ↗
59. KAERI's development of LWR accident-tolerant fuel10.13182/NT13-89 ↗
60. Molybdenum silicide based materials and their properties10.1361/105994999770346837 ↗
61. Effect of roughness of substrate and sputtering power on the properties of TiN coatings deposited by magnetron sputtering for ATF10.1016/j.jnucmat.2018.07.011 ↗
62. Hard chrome coatings deposited by physical vapour deposition10.1016/0040-6090(83)90501-1 ↗
63. Irradiation resistance of vacuum arc chromium coatings for zirconium alloy fuel claddings10.1016/j.jnucmat.2018.07.063 ↗
64. Nickel-chromium (Ni–Cr) coatings deposited by magnetron sputtering for accident tolerant nuclear fuel claddings10.1016/j.surfcoat.2019.04.057 ↗
65. Fuel performance of chromium-coated zirconium alloy and silicon carbide accident tolerant fuel claddings10.1016/j.anucene.2018.06.001 ↗
66. HRTEM and chemical study of an ion-irradiated chromium/zircaloy-4 interface10.1016/j.jnucmat.2018.01.029 ↗
67. Brachet J-C, Le Saux M, Tupin M, et al (2013) Assessment at CEA of coated nuclear fuel cladding for LWRs with increasing margins in LOCA and beyond LOCA conditions Coatings for mechanical applications View project Plasma nitriding of austenitic stainless steel View project 860 ASSESSMENT AT CEA OF CO. 860–867.
68. Behavior of Chromium Coated M5 Claddings under LOCA Conditions
69. High-temperature oxidation behavior of Cr-coated zirconium
70. Fatigue behavior of cold spray – coated accident tolerant
71. Microstructure and oxidation behavior of CrAl laser-coated Zircaloy-4 alloy10.3390/met7020059 ↗
72. The replacement of electroplating10.1016/0257-8972(95)02653-3 ↗
73. Corrosion behavior and surface properties of PVD coatings for mold technology applications10.3390/coatings9010007 ↗
74. Development of chromium and chromium nitride coated cladding for VVER reactors
75. On coating techniques for surface protection: a review
76. Cavaliere · 2018
77. Geelhood · 2019 · PNNL
78. Overview of westinghouse lead accident tolerant fuel program
79. Cold spray coatings for accident tolerant Zr-alloy cladding in light water reactors
80. Westinghouse-Exelon EnCore ® Fuel Lead Test Rod ( LTR ) program including coated cladding development and advanced pellets
81. Development of surface coatings for enhanced accident tolerant fuel
82. In-pile testing of CrN, TiAlN, and AlCrN coatings on Zircaloy cladding in the halden reactor
83. Irradiation creep and growth behavior, and microstructural evolution of advanced Zr-base alloys
84. Allen · 2012
85. Assessment at CEA of coated nuclear fuel cladding for LWRS with increased margins in loca and beyond loca conditions
86. CEA studies on advanced nuclear fuel claddings for enhanced Accident Tolerant LWRs Fuel(LOCA and beyond LOCA conditions). FONTEVRAUD 8- Contrib Mater Investig Oper Exp to LWRs’ Safety
87. Chromium coated nuclear fuel claddings for enhanced accident tolerant LWRs fuel
88. Microstructure investigation of Cr and Cr alloys irradiated with heavy ions10.1016/0022-3115(95)00066-6 ↗
89. High energy heavy ion irradiation of chromium films10.1016/0042-207X(94)00081-6 ↗
90. Irradiation and the ductility of chromium10.1016/0036-9748(68)90195-6 ↗
91. HRTEM and chemical study of an ion-irradiated chromium/zircaloy-4 interface10.1016/j.jnucmat.2018.01.029 ↗
92. Mechanical analysis of surface-coated zircaloy cladding10.1016/j.net.2017.03.012 ↗
93. Su · 2020
94. Brown NR, Wysocki AJ, Terrani KA, et al (2016) Advanced fuels campaign fuel cycle research and development.
95. Zohuri · 2015 · 26
96. Heat transfer – a review of 2002 literature10.1016/j.ijheatmasstransfer.2004.10.011 ↗
97. Whitaker S, Whitaker S, 10 – heat transfer with boiling and condensation (1997), 10.1016/B978-0-08-017866-0.50016-2.
98. Pool boiling critical heat flux (CHF) – part 2: review of mechanisms, models, and correlations10.1016/j.ijheatmasstransfer.2017.09.134 ↗
99. Effect of inclination on saturation boiling of PF-5060 dielectric liquid on 80- and 137-μm thick copper micro-porous surfaces10.1016/j.ijthermalsci.2011.11.004 ↗
100. Pool boiling critical heat flux (CHF) – part 2: assessment of models and correlations10.1016/j.ijheatmasstransfer.2017.09.073 ↗