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

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

doi:10.1016/j.nme.2019.100715

Cited by 34 publications

(8 citation statements)

References 36 publications

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“…The C.A powder had more crystallite size than G.A with a difference of ~0.1nm which reduced to ~0.02 nm in the respective coatings. The broadening and reduction in crystallite size for a coating corresponds to a non-uniform micro-strain [47,48] which is a typical phenomenon observed in CS [49]. Microhardness measurements for powders and respective coatings are listed in Table 6 and Figure 12.…”

Section: Coating Characterizationmentioning

confidence: 99%

An Attempt to Understand Stainless 316 Powders for Cold-spray Deposition

Karmarkar¹,

Varadaraajan²,

Mohanty³

et al. 2023

Preprint

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Cold gas dynamic spray (CS) is a unique technique to deposit material using high strain rate solid state deformation. A major challenge for this technique is its dependence on the powder properties and lack of standards to assess them between lots and manufacturers. The motivation of this research was to understand the variability in powder atomization techniques for stainless steel powders and their subsequent properties for their corresponding impact on CS. A drastic difference (~30%) was observed in deposition efficiencies (DE) of unaltered, spherical, and similar sized stainless steel (316) powders produced using centrifugal (C.A) and traditional gas atomization (G.A) techniques. The study highlights more on differences on precursor level. Using recent advancements in large scale statistical measurements like laser diffraction shape analysis, µCT scanning, traditional methods like EBSD, nano-indentation, an attempt is made to understand the powder property. Insights on powder size and shape are documented. Significant differences were observed between C.A and G.A powders in terms of grain size, fraction of higher angle grain boundaries (HAGB) and nano hardness. The outcomes of this study would be helpful to understand the commercialization of the cold-spray process for bulk manufacturing of powder precursors

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Section: Coating Characterizationmentioning

confidence: 99%

An Attempt to Understand Stainless 316 Powders for Cold-spray Deposition

Karmarkar¹,

Varadaraajan²,

Mohanty³

et al. 2023

Preprint

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“…There was no void formation or Cr-enriched phases in 10Cr and 13Cr FeCrAl alloys, and irradiation-induced defects only contributed to hardening. Dabney et al showed that thick FeCrAl coatings obtained by cold spraying demonstrate high oxidation resistance during autoclave tests and HT oxidation in the air [84]. However, a fast diffusion of Fe from FeCrAl coating to Zr alloys caused a thick interlayer composed of (Fe,Cr) 2 Zr, FeZr 3 and FeZr 2 Laves phases (Figure 3a,b) [85].…”

Section: Fe-based Coatingsmentioning

confidence: 99%

“…However, a fast diffusion of Fe from FeCrAl coating to Zr alloys caused a thick interlayer composed of (Fe,Cr)2Zr, FeZr3 and FeZr2 Laves phases (Figure 3a,b) [85]. [84] with permission by Elsevier.…”

Section: Fe-based Coatingsmentioning

confidence: 99%

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Recent Advances in Protective Coatings for Accident Tolerant Zr-Based Fuel Claddings

et al. 2021

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Zirconium-based alloys have served the nuclear industry for several decades due to their acceptable properties for nuclear cores of light water reactors (LWRs). However, severe accidents in LWRs have directed research and development of accident tolerant fuel (ATF) concepts that aim to improve nuclear fuel safety during normal operation, operational transients and possible accident scenarios. This review introduces the latest results in the development of protective coatings for ATF claddings based on Zr alloys, involving their behavior under normal and accident conditions in LWRs. Great attention has been paid to the protection and oxidation mechanisms of coated claddings, as well as to the mutual interdiffusion between coatings and zirconium alloys. An overview of recent developments in barrier coatings is introduced, and possible barrier layers and structure designs for suppressing mutual diffusion are proposed.

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“…Several coatings, such as metal coatings (Cr [5][6][7][8][9], Mo [10] and FeCrAl [11]), ceramic coatings (TiAlCrN [1] and Ti 2 AlC [12,13]), and multilayer coatings (Cr-Zr/Cr/CrN [14] and TiN/TiAlN [1]), have been carried out under high-temperature conditions. Although the above various coatings exhibit exceptional corrosion resistance, many significant challenges remain in fuel cladding applications.…”

Section: Introductionmentioning

confidence: 99%

Oxidation Behavior of FeCoNiCrMo High-Entropy Coatings by Atmospheric Plasma Spraying on Zircaloy-4 in Steam at 1100 °C

Wen

Yang

et al. 2022

Crystals

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As a potential accident-tolerant fuel cladding material, we studied the method of preparing FeCoNiCrMo coatings on zircaloy-4 substrates by atmospheric plasma spraying (APS) technology to explore the high-temperature oxidation behavior of the FeCoNiCrMo coatings at 1100 °C in high-temperature steam. Various surface analysis techniques such as X-ray diffraction, electron probe microanalysis, and scanning electron microscopy were used to analyze the phase composition and microstructure of the oxidized products. The oxidation behavior of the FeCoNiCrMo coatings and the diffusion of the FeCoNiCrMo coatings to the zircaloy-4 substrates were analyzed. After oxidation at 1100 °C, a dense Cr2O3 oxide layer was formed on the coating’s surface, which grew from 1.5 to 3 μm after 15 to 60 min of oxidation, and the FeCoNiCrMo coatings and the substrates diffused simultaneously. The oxidation tests showed that the FeCoNiCrMo coatings prepared by APS can effectively delay the oxidation of zircaloy-4 substrates.

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

Cited by 34 publications

References 36 publications

An Attempt to Understand Stainless 316 Powders for Cold-spray Deposition

An Attempt to Understand Stainless 316 Powders for Cold-spray Deposition

Recent Advances in Protective Coatings for Accident Tolerant Zr-Based Fuel Claddings

Oxidation Behavior of FeCoNiCrMo High-Entropy Coatings by Atmospheric Plasma Spraying on Zircaloy-4 in Steam at 1100 °C

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