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

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

doi:10.1016/j.jnucmat.2018.05.014

Cited by 69 publications

(11 citation statements)

References 31 publications

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“…Yeom et al [ 74 ] showed that Mo diffusion barrier layer between FeCrAl coating and Zr-alloy substrate is essential for accident tolerant fuel applications. To enhance oxidation resistance at high temperatures (>1000 °C) in the event of loss of coolant accident (LOCA), the cold spray process was investigated for the deposition of FeCrAl coatings on optimized ZIRLO™ fuel cladding tubes.…”

Section: Recent Advances In Hydrogen Permeation Barriersmentioning

confidence: 99%

Recent Advances and Prospects in Design of Hydrogen Permeation Barrier Materials for Energy Applications—A Review

2022

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The hydrogen infrastructure involves hydrogen production, storage and delivery for utilization with clean energy applications. Hydrogen ingress into structural materials can be detrimental due to corrosion and embrittlement. To enable safe operation in applications that need protection from hydrogen isotopes, this review article summarizes most recent advances in materials design and performance characterization of barrier coatings to prevent hydrogen isotopes’ absorption ingress and permeation. Barriers are crucial to prevent hydride formation and unwanted hydrogen effects to increase safety, materials’ lifetime and reduce cost for applications within nuclear and renewable energy. The coating may be applied on a material that requires protection from hydrogen pick-up, transport and hydride formation in hydrogen storage containers, in pipelines, spent nuclear fuel storage or in nuclear reactors. While existing, commercial coatings that have been much in use may be satisfactory for various applications, it is desirable to evaluate whether alternative coating concepts can provide a greater resistance to hydrogen isotope permeation along with other improved properties, such as mechanical strength and thermal resistance. The information presented here is focusing on recent findings within the past 5–7 years of promising hydrogen barriers including oxides, nitrides, carbon, carbide, MAX-phases and metals and their mechanical strength, hydrogen pick-up, radiation resistance and coating manufacturing techniques. A brief introduction to hydrogen permeation is provided. Knowledge gaps were identified to provide guidance for material’s research prospects.

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Section: Recent Advances In Hydrogen Permeation Barriersmentioning

confidence: 99%

Recent Advances and Prospects in Design of Hydrogen Permeation Barrier Materials for Energy Applications—A Review

2022

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“…Several high-melted metals, such as Ta, Mo, and Re, are suggested to apply as a barrier sublayers for Cr-coated Zr alloys [26]. Molybdenum has been used to effectively suppress the Cr-Zr interdiffusion layer formation [26,32,33]. Mo satisfies a number of parameters that are important for intermediate sublayer, such as a good adhesion strength and similar thermal expansion coefficients to chromium coating and zirconium alloy [26,32].…”

Section: Introductionmentioning

confidence: 99%

High-Temperature Steam Oxidation of Accident-Tolerant Cr/Mo-Coated Zr Alloy at 1200–1400 °C

et al. 2023

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The oxidation resistance under LOCA conditions of bilayer Cr/Mo coating deposited on Zr-1Nb zirconium alloy was investigated in this paper. The bilayer Cr (8 μm)/Mo (3 μm) coatings were deposited by magnetron sputtering. Then, oxidation resistance under high-temperature oxidation at 1200–1400 °C in a water steam was studied. The use of a Mo sublayer resulted in limiting Cr–Zr interdiffusion under high-temperature oxidation. It was shown that the Mo barrier sublayer (~3 μm) can provide the protective behavior of the Cr/Mo-coated Zr at 1330 °C in a water steam for at least 720 s. The weight gain of the bilayer Cr/Mo samples was comparable with the monolayer Cr samples after oxidation at 1400 °C. In addition, the analysis of the Cr/Mo-coated Zr alloy oxidation behavior at 1400 °C was carried out.

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“…The second approach, referred to as ATF-coated cladding, is to prepare coatings on the existing Zr alloy claddings, which is the most promising for engineering implementation within the short term. Consequently, many coatings such as Cr and Cr-based alloys [ 14 , 15 , 16 ], nitride ceramics [ 17 , 18 , 19 ], FeCrAl alloys [ 20 , 21 , 22 ] and MAX phase ceramics [ 23 , 24 , 25 ] are used worldwide. Among them, Cr coatings show resistance to pressurized-water corrosion [ 26 , 27 ], friction and wear [ 16 , 28 ], high-temperature steam oxidation [ 29 , 30 , 31 , 32 ] and ion or neutron irradiation [ 33 , 34 , 35 , 36 ], and hence become the most promising candidate for advanced ATF cladding coatings.…”

Section: Introductionmentioning

confidence: 99%

An Orthogonal Experimental Study on the Preparation of Cr Coatings on Long-Size Zr Alloy Tubes by Arc Ion Plating

Chen

Wang

et al. 2022

Materials

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Cr-coated Zr alloys are widely considered the most promising accident-tolerant fuel (ATF) cladding materials for engineering applications in the near term. In this work, Cr coatings were prepared on the surfaces of 1400 mm long N36 cladding tubes using an industrial multiple arc source system. Orthogonal analyses were conducted to demonstrate the significance level of various process parameters influencing the characteristics of coatings (surface roughness, defects, crystal orientation, grain structure, etc.). The results show that the arc current mainly affects the coating deposition rate and the droplet particles on the surface or inside the coatings; however, the crystal preferred orientation and grain structure are more significantly influenced by the gas pressure and negative bias voltage, respectively. Then, the underlying mechanisms are carefully discussed. At last, a set of systemic methods to control the quality and microstructures of Cr coatings are summarized.

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

Cited by 69 publications

References 31 publications

Recent Advances and Prospects in Design of Hydrogen Permeation Barrier Materials for Energy Applications—A Review

Recent Advances and Prospects in Design of Hydrogen Permeation Barrier Materials for Energy Applications—A Review

High-Temperature Steam Oxidation of Accident-Tolerant Cr/Mo-Coated Zr Alloy at 1200–1400 °C

An Orthogonal Experimental Study on the Preparation of Cr Coatings on Long-Size Zr Alloy Tubes by Arc Ion Plating

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