effects of cold spray chromium coatings on the properties of … · 2019-06-26 · –formation of...
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Westinghouse Non-Proprietary Class 3 © 2019 Westinghouse Electric Company LLC. All Rights Reserved.
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J.E. Romero, J.L. Walters, A.J. Mueller, B.R. Maier, J.M. Partezana,
J.L. Lyons, W.A. Byers, G. Wang, A. Parsi, R.S. Stiteler, M. Limbäck
19th International Symposium on Zirconium in the Nuclear Industry
May 20th , 2019
Effects of Cold Spray Chromium Coatings on the
Properties of Zirconium Alloys
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Outline
• Cold spray chromium coating– Development
– Manufacturing scale-up
• Corrosion performance
– Normal operating conditions
– Steam at high temperature
– Interdiffusion and eutectics
• Thermo-mechanical performance
– Tensile tests
– Burst Tests
• Summary
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Cold Spray
• Deposition of chromium in solid state– Powder particles propelled at supersonic velocity
• No significant preparation of substrate or vacuum required
King et al. (2009)Assadi et al. (2016)
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Chromium-coated Cladding
• Thin adherent and dense chromium layer
• Cold spray as deposition technology
• Polishing process applied for finishing
• Substrate cladding unchanged
Chromium Coating
Optimized ZIRLO™ Cladding
20 µm
As-fabricated Chromium-coated Zirconium Cladding
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Manufacturing Scale-up
Coating and polishing of full length tubes qualified
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Corrosion - Normal Operation
Corrosion of coated areas near zero
Uniform CorrosionAutoclave
PWR Water
360°C
Open Samples
Weight gain of coated samples
primarily from uncoated inner
diameter
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Corrosion - High Temperature Steam
200 µm
Non-Coated Coated
200 µm
Minimal oxidation and retained ductility with coatings
during severe accident conditions
1200°C for one hour 1200°C for one hour
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Corrosion – High Temperature Steam
Uncoated 10 mm 10 mmCoated
200 µm200 µm
Protection of coating prevents oxygen strengthening
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Interdiffusion
Oxygen Chromium Zirconium
Cr
Cr-Zr
Zr
Cr2O3
50 µm
1300°C for 5 minutes
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Interdiffusion and Eutectic Formation
1300°C for 20 minutes
Prior -Zr
ZrO2
(O)-Zr and Cr-Zr
200 µm 200 µm
Cr2O3 and Cr
Prior -Zr
Cr-Zr
Eutectic
Cr2O3
Cavity
Deep diffusion of chromium leads to
eutectics, melting and cavitation
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Thermo-mechanical – Tensile Tests
• No significant effect on mechanical properties of substrate
• Coating remains adherent even at high strain
Type Sample Yield Stress Ultimate Strength Elongation
Coated A 1.16 1.19 1.46
Coated B 1.18 1.21 1.33
Coated C 1.17 1.20 1.46
Opt. ZIRLO Reference A 1.11 1.15 1.92
Opt. ZIRLO Reference B 1.11 1.15 1.92
Opt. ZIRLO Specification NA 1.00 1.00 1.00
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Thermo-mechanical – Thermal Creep
• Creep strain decreases with increased coating thickness
• General strengthening effect of chromium– Stronger material surrounding standard cladding
Material Sample Coating
Thickness (µm)
OD Strain
Ratio
Midwall Strain
Ratio
Chromium Coated
Cladding
A-1 18 0.76 0.76
A-2 18 0.69 0.69
B-1 42 0.59 0.59
B-2 42 0.57 0.57
ZIRLO® Reference NA 0 1.00 1.00
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Thermo-mechanical - Burst
1.4 MPa
Coated
Non-Coated
5.5 MPa 12.4 MPa
1 mm
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Performance Under Irradiation
No observable degradation during irradiation
50 µm
As-fabricated Irradiated Irradiated to 0.8 dpa
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Summary
• Cold spray chromium coatings developed for fuel cladding
• Significant benefits on corrosion resistance– Normal operation and high temperature
– Suppression of oxygen diffusion inhibits strengthening
• Positive effects on mechanical performance– Basic mechanical properties unaffected
– Improved burst and thermal creep behavior
• Inter-diffusion leads to metallurgical phenomena– Formation of intermetallics
– Deep diffusion in the presence of oxygen
– Formation of eutectics, melting and cavitation