Advances in High-temperature Steam Oxidation of Microarc Oxidation Coatings and Cr-based Composite Coatings on Zirconium Fuel Claddings

XUE Wenbin; LI Xin; WANG Lijiao; CHAI Luqi; ZHOU Qian; WANG Xingping; XU Chi; JIN Xiaoyue; DU Jiancheng

doi:10.16490/j.cnki.issn.1001-3660.2025.15.001

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Surface Technology ›› 2025, Vol. 54 ›› Issue (15) : 1-23. DOI: 10.16490/j.cnki.issn.1001-3660.2025.15.001

Advances in High-temperature Steam Oxidation of Microarc Oxidation Coatings and Cr-based Composite Coatings on Zirconium Fuel Claddings

XUE Wenbin^{1, 2, 3}, LI Xin¹, WANG Lijiao¹, CHAI Luqi¹, ZHOU Qian¹, WANG Xingping⁴, XU Chi^{1, 2, 3}, JIN Xiaoyue², DU Jiancheng¹

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Abstract

Zirconium alloys have been used as reactor structural materials such as fuel claddings in light water reactors (LWRs) owing to their low neutron capture cross section, good mechanical performance and corrosion resistance. However, the fuel claddings will undergo severe high-temperature steam oxidation under the loss-of-coolant accident (LOCA) condition, and the hydrogen released from oxidation of Zr with water vapor might also trigger severe hydrogen explosion accidents. In recent years, accident tolerant fuel (ATF) has been proposed to reduce the steam oxidation rate and widen the safety margin under normal operation condition. One of the most important ATF concepts is to develop the steam oxidation-resistant coatings on Zr cladding. Up to now, the Cr has been considered to be a potential coating material for Zr cladding, because a dense Cr₂O₃ layer can be formed to significantly suppress oxygen diffusion inwards. An insulating MAO interlayer between the Cr layer and Zr substrate can be designed to suppress the Cr/Zr inter-diffusion in the high-temperature steam and the galvanic corrosion between Cr layer and Zr substrate in high-temperature lithium borate solution under normal operation condition. The work aims to introduce the preparation process and microstructure of both the MAO coating and MAO/Cr composite coating on Zr and its alloys. The present advances about the oxidation kinetics curves, the evolution of microstructure and composition of these coatings in 900-1 200 ℃ steam environment were emphasized, and the effect of Al and Si alloying elements on the high-temperature oxidation behavior of MAO/Cr-based composite coating was analyzed. Furthermore, the high energy ion irradiation effect for MAO/Cr-based composite coating was also briefly introduced. Finally, the future research topics about MAO/Cr-based composite coatings were suggested. It is found that the MAO coating and MAO/Cr-based composite coating on Zr alloys have excellent steam oxidation resistance. However, the MAO coating will fail above 1 100 ℃, while the MAO/Cr composite coating still keeps excellent steam oxidation resistance at 1 100 ℃. In addition, the MAO insulating interlayer between the Cr layer and Zr substrate can suppress the Cr and Zr inter-diffusion in high-temperature environment. The addition of Al and Si elements in the Cr outer layer can further improve the oxidation resistance of MAO/Cr coating, which is ascribed to the formation of Al₂O₃barrier layer in MAO/CrAl composite coating and Zr₂Si barrier layer in MAO/CrAlSi composite coating, respectively.

Key words

microarc oxidation / zirconium fuel claddings / steam oxidation / Cr-based composite coatings / inter-diffusion

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XUE Wenbin, LI Xin, WANG Lijiao, CHAI Luqi, ZHOU Qian, WANG Xingping, XU Chi, JIN Xiaoyue, DU Jiancheng. Advances in High-temperature Steam Oxidation of Microarc Oxidation Coatings and Cr-based Composite Coatings on Zirconium Fuel Claddings[J]. Surface Technology. 2025, 54(15): 1-23 https://doi.org/10.16490/j.cnki.issn.1001-3660.2025.15.001

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Funding

National Natural Science Foundation of China (12405329); Nuclear Materials Innovation Foundation (ICNM-2022-YZ-02, ICNM-2020-YZ-04); Open Fund of Key Laboratory of Beam Technology of Ministry of Education (BEAM2024G03)