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Title: Experimental evaluation of cold spray FeCrAl alloys coated zirconium-alloy for potential accident tolerant fuel cladding

Abstract

Two FeCrAl alloy coatings with different Cr and Al contents were deposited on Zr-alloy substrates via the cold spray deposition method to study the efficacy of these coatings to improve the accident tolerance of Zr-alloy fuel cladding in light water reactors (LWRs). First, the coatings were tested in a 400 °C steam autoclave for 72 h as an accelerated method to simulate the normal LWR operating conditions. In these tests, both coatings resulted in notable improvements in oxidation resistance compared to the Zr-alloy, with the higher Cr containing coating exhibiting a thinner oxide layer. Both coatings provided good oxidation resistance when tested in 1200 °C ambient air environment; however, the formation of a low melting point eutectic (~928 °C) between Fe and Zr resulted in significant melting associated with inter-diffusion between Fe in the coating and the Zr in the substrate. Therefore, to take advantage of the superior oxidation resistance that FeCrAl coatings can provide, a Mo interlayer was deposited, also by the cold spray process, in-between the protective FeCrAl coating and the Zr-alloy substrate, thus creating a dual cold spray layer accident tolerant coated cladding concept. The wear resistance of the FeCrAl coating was superior to the Zr-alloy substratemore » based on pin-on-disk wear tests, providing an indication of the benefits of such coatings to reduce grit-to-rod fretting (GTRF) damage. The feedstock powders, microstructure, phases, hardness of coatings, as well as oxide and inter-diffusion layers of oxidized coatings were examined using SEM, XRD, and XPS characterization techniques.« less

Authors:
ORCiD logo; ; ; ; ;
Publication Date:
Research Org.:
Westinghouse Electric Company LLC, Cranberry Township, PA (United States); Massachusetts Inst. of Technology (MIT), Cambridge, MA (United States)
Sponsoring Org.:
USDOE Office of Nuclear Energy (NE)
OSTI Identifier:
1575317
Alternate Identifier(s):
OSTI ID: 1801186
Grant/Contract Number:  
NE0008222; NE0008416
Resource Type:
Published Article
Journal Name:
Nuclear Materials and Energy
Additional Journal Information:
Journal Name: Nuclear Materials and Energy Journal Volume: 21 Journal Issue: C; Journal ID: ISSN 2352-1791
Publisher:
Elsevier
Country of Publication:
Netherlands
Language:
English
Subject:
73 NUCLEAR PHYSICS AND RADIATION PHYSICS; Nuclear Science & Technology; Zircaloy-4FeCrAl coating; Cold spray process; High temperature oxidation; Interdiffusion barrier

Citation Formats

Dabney, Tyler, Johnson, Greg, Yeom, Hwasung, Maier, Ben, Walters, Jorie, and Sridharan, Kumar. Experimental evaluation of cold spray FeCrAl alloys coated zirconium-alloy for potential accident tolerant fuel cladding. Netherlands: N. p., 2019. Web. doi:10.1016/j.nme.2019.100715.
Dabney, Tyler, Johnson, Greg, Yeom, Hwasung, Maier, Ben, Walters, Jorie, & Sridharan, Kumar. Experimental evaluation of cold spray FeCrAl alloys coated zirconium-alloy for potential accident tolerant fuel cladding. Netherlands. https://doi.org/10.1016/j.nme.2019.100715
Dabney, Tyler, Johnson, Greg, Yeom, Hwasung, Maier, Ben, Walters, Jorie, and Sridharan, Kumar. Sun . "Experimental evaluation of cold spray FeCrAl alloys coated zirconium-alloy for potential accident tolerant fuel cladding". Netherlands. https://doi.org/10.1016/j.nme.2019.100715.
@article{osti_1575317,
title = {Experimental evaluation of cold spray FeCrAl alloys coated zirconium-alloy for potential accident tolerant fuel cladding},
author = {Dabney, Tyler and Johnson, Greg and Yeom, Hwasung and Maier, Ben and Walters, Jorie and Sridharan, Kumar},
abstractNote = {Two FeCrAl alloy coatings with different Cr and Al contents were deposited on Zr-alloy substrates via the cold spray deposition method to study the efficacy of these coatings to improve the accident tolerance of Zr-alloy fuel cladding in light water reactors (LWRs). First, the coatings were tested in a 400 °C steam autoclave for 72 h as an accelerated method to simulate the normal LWR operating conditions. In these tests, both coatings resulted in notable improvements in oxidation resistance compared to the Zr-alloy, with the higher Cr containing coating exhibiting a thinner oxide layer. Both coatings provided good oxidation resistance when tested in 1200 °C ambient air environment; however, the formation of a low melting point eutectic (~928 °C) between Fe and Zr resulted in significant melting associated with inter-diffusion between Fe in the coating and the Zr in the substrate. Therefore, to take advantage of the superior oxidation resistance that FeCrAl coatings can provide, a Mo interlayer was deposited, also by the cold spray process, in-between the protective FeCrAl coating and the Zr-alloy substrate, thus creating a dual cold spray layer accident tolerant coated cladding concept. The wear resistance of the FeCrAl coating was superior to the Zr-alloy substrate based on pin-on-disk wear tests, providing an indication of the benefits of such coatings to reduce grit-to-rod fretting (GTRF) damage. The feedstock powders, microstructure, phases, hardness of coatings, as well as oxide and inter-diffusion layers of oxidized coatings were examined using SEM, XRD, and XPS characterization techniques.},
doi = {10.1016/j.nme.2019.100715},
journal = {Nuclear Materials and Energy},
number = C,
volume = 21,
place = {Netherlands},
year = {2019},
month = {12}
}

Journal Article:
Free Publicly Available Full Text
Publisher's Version of Record
https://doi.org/10.1016/j.nme.2019.100715

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