Enhanced flow boiling heat transfer on chromium coated zircaloy-4 using cold spray technique for accident tolerant fuel (ATF) materials

Lee, Donghwi; Elward, Barret; Brooks, Paul; Umretiya, Rajnikant; Rojas, Jessika; Bucci, Matteo; Rebak, Raul B.; Anderson, Mark

doi:10.1016/j.applthermaleng.2020.116347

Enhanced flow boiling heat transfer on chromium coated zircaloy-4 using cold spray technique for accident tolerant fuel (ATF) materials

Journal Article · Sun Nov 29 23:00:00 EST 2020 · Applied Thermal Engineering

DOI:https://doi.org/10.1016/j.applthermaleng.2020.116347· OSTI ID:1848091

Lee, Donghwi ^[1]; Elward, Barret ^[2]; Brooks, Paul ^[2]; Umretiya, Rajnikant ^[3]; Rojas, Jessika ^[3]; Bucci, Matteo ^[4]; Rebak, Raul B. ^[5]; Anderson, Mark ^[2]

Univ. of Wisconsin, Madison, WI (United States). Dept. of Mechanical Engineering; Univ. of Wisconsin, Madison, WI (United States)
Univ. of Wisconsin, Madison, WI (United States). Dept. of Mechanical Engineering
Virginia Commonwealth Univ., Richmond, VA (United States). Dept. of Mechanical and Nuclear Engineering
Massachusetts Inst. of Technology (MIT), Cambridge, MA (United States). Dept. of Nuclear Science and Engineering
GE Global Research, Schenectady, NY (United States)

Flow boiling heat transfer tests were conducted to evaluate the Critical Heat Flux (CHF) and Heat Transfer Coefficient (HTC) of conventional and accident tolerant fuel (ATF) cladding materials, i.e., bare Zircaloy-4 (Zr4), and Zircaloy-4 coated with Chromium using physical vapor deposition (PVD) (Zr4-Cr-PVD) and cold spray process (Zr4-Cr-CS), respectively. The tests were performed on a single heater rod with a uniform heat flux profile, at the atmospheric pressure, inlet temperature (24 °C) and mass flow rate (750 kg/m²s). HTC’s were increased by 5.2% and 3.3% on Zr4-Cr-CS compared to bare Zr4 and Zr4-Cr-PVD. Improved HTCwas attributed to the increased void fraction and high roughness (Ra = 532 nm) of the Zr4-Cr-CS. In detail, the micro-cavities, which act as bubble seeds, were entirely distributed on the Zr4-Cr-CS, and these micro-cavities generated smaller and faster bubbles, thus the void fraction increased by 10.9% compared to bare Zr4. HTC is improved by these smaller and faster bubbles which can remove heat from the heater rod surface more efficiently. To identify the exact location of CHF, the surface temperature profile was measured using advanced fiber-optic sensors which have high temporal/spatial resolution (distance between point to point: ~2.5 mm, frequency ~100 Hz). CHF occurred at 80–95% along the heated length and showed an 11.6% reduction on Zr4-Cr-CS compared to bare Zr4. We hypothesize the CHF reduction was caused by the lower wettability of the Zr4-Cr-CS which reduces the liquid supply to the surface, and vigorous bubble accumulation owing to high void fraction near the outlet, which results in early formation of the vapor film. During the post-CHF quenching phase, the rougher Zr4-Cr-CS showed larger cooling rates compared to the bare Zr4 and Zr4-Cr-PVD, preventing of oxidation by chromium layer. In conclusion, we demonstrate that the high roughness on the Zr4-Cr-CS increased the number of micro-cavities on the surface, resulting in 5.2% increase in HTC and improvement in the quenching heat transfer performance whereas CHF was 11.6% reduced compared to bare Zr4. Overall statistically there is little effect in the coating with regards to CHF and slight improvement in HTC.

View Accepted Manuscript (DOE)

Research Organization:: University of Wisconsin, Madison, WI (United States)

Sponsoring Organization:: USDOE Office of Nuclear Energy (NE)

Grant/Contract Number:: NE0008546

OSTI ID:: 1848091

Alternate ID(s):: OSTI ID: 1811097
OSTI ID: 23191803

Journal Information:: Applied Thermal Engineering, Journal Name: Applied Thermal Engineering Journal Issue: C Vol. 185; ISSN 1359-4311

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Enhanced flow boiling heat transfer on chromium coated zircaloy-4 using cold spray technique for accident tolerant fuel (ATF) materials

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