Effective coating morphology to protect zr alloy cladding from oxidation and hydriding

Patent metadata

Field	Value
Publication number	US-2024212870-A1
Application number	US-202218069864-A
Country	US
Kind code	A1
Filing date	Dec 21, 2022
Priority date	Dec 21, 2022
Publication date	Jun 27, 2024
Grant date	—

Abstract

A coating for protecting a Zirconium alloy based layer of a nuclear fuel rod cladding is provided. The coating comprises a primary layer. A microstructure of the primary layer is comprised of a number of grains and is randomized. The primary layer is configured with a density of about 94.5% or greater. A cladding for a nuclear fuel rod and a method for producing a cladding for a nuclear fuel rod are also provided.

First claim

What is claimed is:

1 . A coating for protecting a Zirconium alloy based layer of a nuclear fuel rod cladding, the coating comprising a primary layer, wherein:
a microstructure of the primary layer is comprised of a number of grains and is randomized; and the primary layer is configured with a density of about 94.5% or greater.

2 . The coating as claimed in claim 1 , wherein the primary layer has a thickness in the range of about 4 microns to about 40 microns.

3 . The coating as claimed in claim 1 , wherein the primary layer comprises a Chromium-based metallic layer.

4 . The coating as claimed in claim 3 , wherein the Chromium-based metallic layer is comprised of a Chromium-based alloy.

5 . The coating as claimed in claim 1 , wherein the coating comprises a ceramic layer.

6 . The coating as claimed in claim 5 , wherein the ceramic layer is comprised of Zirconium Dioxide or a Chromium-based material comprising at least one of Niobium, Nitrogen, Silicon, or Carbon.

7 . The coating as claimed in claim 5 , wherein the ceramic layer is the primary layer.

8 . The coating as claimed in claim 5 , wherein the ceramic layer is positioned around the primary layer.

9 . The coating as claimed in claim 8 , wherein the ceramic layer has a thickness in the range of about 1 micron to about 10 microns.

10 . The coating as claimed in claim 8 , wherein the ceramic layer is configured with a density of about 94.5% or greater.

11 . The coating as claimed in claim 1 , wherein the coating comprises an interlayer positioned between the Zirconium alloy based layer and the primary layer.

12 . The coating as claimed in claim 11 , wherein the interlayer has a thickness in the range of about 0.5 to about 4 microns.

13 . The coating as claimed in claim 11 , wherein the interlayer is configured to inhibit a chemical interaction between the Zirconium alloy and the primary layer.

14 . The coating as claimed in claim 13 , wherein the interlayer is comprised of Niobium, Molybdenum, Tantalum, Rhenium, Osmium, Ruthenium, Tungsten, or an alloy comprising any combination thereof.

15 . The coating as claimed in claim 1 , wherein the primary layer is configured with a density of at least 95%.

16 . The coating as claimed in claim 1 , wherein the geometry of each of the number of grains comprises:
an axial component in the range of about 1 micron to about 50 microns; and a radial component in the range of about 1 micron to about 10 microns.

17 . A cladding for a nuclear fuel rod, the cladding comprising:
a Zirconium alloy tube configured to house an amount of nuclear fuel; and a coating deposited onto an outer surface of the Zirconium alloy tube, the coating comprising a Chromium-based layer, the Chromium-based layer having a randomized grain structure and a density of at least 95%.

18 . A method for producing a cladding for a nuclear fuel rod, the method comprising:
providing a base layer for the cladding, wherein the base layer is comprised of a Zirconium alloy; and protecting the base layer, the protecting comprising depositing a coating onto the base layer, wherein the coating comprises a Chromium-based layer; and
wherein the Chromium-based layer of the protected base layer has a randomized microstructure and a density of about 95% or greater.

19 . The method as claimed in claim 18 , wherein the protecting comprises depositing the Chromium-based layer with a cold spray process, a thermal spray process, or a Physical Vapor Deposition process.

20 . The method as claimed in claim 18 , wherein the protecting comprises mechanically working the deposited at least one layer.

Assignees

• Westinghouse Electric Co Llc

Inventors

• Lahoda Edward J
• Roberts Elwyn
• Maier Benjamin R
• Jaworski Jr Allan Wayne
• Parsi Arash
• Wang Guoqiang
• Byers William A
• Walters Jorie
• Vallencour Chona P
• Lyons John Leo
• Czerniak Luke
• Matway Roy J
• Roberts Gregory E
• Metzger Kathryn E
• Wright Jonathan
• Olson Luke C
• Adorno-Lopes Denise

Classifications

• Y02E30/30

  Nuclear fission reactors · CPC title

• C23C28/3455

  with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer · CPC title

• C23C28/321

  with at least one metal alloy layer · CPC title

• C23C28/32

  including at least one pure metallic layer · CPC title

• C23C28/34

  including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates · CPC title