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

Dabney, Tyler; Johnson, Greg; Yeom, Hwasung; Maier, Ben; Walters, Jorie; Sridharan, Kumar

doi:10.1016/j.nme.2019.100715

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 »« less

Authors:

; Johnson, Greg; Yeom, Hwasung; Maier, Ben; Walters, Jorie; Sridharan, Kumar

Publication Date:: 2019-12-01

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.

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                    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

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                    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.

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@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}

}

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

Abstract

Citation Formats

Development of cold spray process for oxidation-resistant FeCrAl and Mo diffusion barrier coatings on optimized ZIRLO™ journal, August 2018

Enhanced pool boiling critical heat flux with a FeCrAl layer fabricated by DC sputtering journal, November 2016

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Review of Relationship Between Particle Deformation, Coating Microstructure, and Properties in High-Pressure Cold Spray journal, June 2017

The solid solubility of Fe in α-Zr: A secondary ion mass spectrometry study journal, June 1994

Behavior of an improved Zr fuel cladding with oxidation resistant coating under loss-of-coolant accident conditions journal, December 2016

High-temperature reaction of oxygen-stabilized α-Zr(O) with nitrogen journal, April 2014

Microstructure and mechanical properties of Laves phase-reinforced Fe–Zr–Cr alloys journal, July 2009

Microstructure and mechanical behavior of Zr substrates coated with FeCrAl and Mo by cold-spraying journal, June 2018

A comparative study on the wear behaviors of cladding candidates for accident-tolerant fuel journal, October 2015

Some considerations on the mitigation of fretting damage by the application of surface-modification technologies journal, March 2000

Development and property evaluation of nuclear grade wrought FeCrAl fuel cladding for light water reactors journal, December 2015

Performance of iron–chromium–aluminum alloy surface coatings on Zircaloy 2 under high-temperature steam and normal BWR operating conditions journal, March 2016

Microstructure and high temperature mechanical properties of as-cast FeCrAl alloys journal, May 2018

Fe-Zr (iron-zirconium) journal, October 1993

Thermodynamic assessment of the Mo-Zr system journal, March 2002

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Theoretical and experimental comparative study about magnetic behavior of Fe-Al alloys in the high Fe concentration region journal, February 2018

A review of the oxidation behaviour of structural alloys in steam journal, May 2010

Fretting wear comparison of cladding materials for reactor fuel cladding application journal, September 2018

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Fast diffusion of 59 Fe in β-Zr and β-Zr-Fe alloys journal, November 1990

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Enhanced pool boiling critical heat flux with a FeCrAl layer fabricated by DC sputtering
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Materials challenges in nuclear energy
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Review of Relationship Between Particle Deformation, Coating Microstructure, and Properties in High-Pressure Cold Spray
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Behavior of an improved Zr fuel cladding with oxidation resistant coating under loss-of-coolant accident conditions
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A comparative study on the wear behaviors of cladding candidates for accident-tolerant fuel
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Some considerations on the mitigation of fretting damage by the application of surface-modification technologies
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Development and property evaluation of nuclear grade wrought FeCrAl fuel cladding for light water reactors
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Theoretical and experimental comparative study about magnetic behavior of Fe-Al alloys in the high Fe concentration region
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A review of the oxidation behaviour of structural alloys in steam
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Mossbauer effect study of magnetic properties of Fe _1-q Al _q , 0
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Advanced oxidation-resistant iron-based alloys for LWR fuel cladding
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High temperature oxidation of fuel cladding candidate materials in steam–hydrogen environments
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