Antoine Ambard

Identification and characterization of a new zirconium hydride

Zirconium alloys are currently used in nuclear power plants where they are susceptible to hydrogen pick‐up. Hydride precipitation may occur when the hydrogen solubility limit is reached. Various Zr hydride phases, γ, δ and ɛ have been identified since the 1950s. Combining electron precession microdiffraction, electron energy loss spectroscopy and ab initio electronic calculations, a new Zr hydride named ζ has been identified and characterized. It belongs to the trigonal crystal system with space group P3 m1 and it is fully coherent with the αZr matrix.

Studies regarding corrosion mechanisms in zirconium alloys

Understanding the key corrosion mechanisms in a light water reactor primary water environment is critical to developing and exploiting improved zirconium alloy fuel cladding. In this paper, we report recent research highlights from a new collaborative research programme involving 3 U.K. universities and 5 partners from the nuclear industry. A major part of our strategy is to use the most advanced analytical tools to characterise the oxide and metal/oxide interface microstructure, residual stresses, as well as the transport properties of the oxide. These techniques include three-dimensional atom probe (3DAP), advanced transmission electron microscopy (TEM), synchrotron X-ray diffraction, Raman spectroscopy, and in situ electro-impedance spectroscopy. Synchrotron X-ray studies have enabled the characterisation of stresses, tetragonal phase fraction, and texture in the oxide as well as the stresses in the metal substrate. It was found that in the thick oxide (here, Optimized-ZIRLO, a trademark of the Westinghouse Electric Company, tested at 415°C in steam) a significant stress profile can be observed, which cannot be explained by metal substrate creep alone but that local delamination of the oxide layers due to crack formation must also play an important role. It was also found that the oxide stresses in the monoclinic and tetragonal phases grown on Zircaloy-4 (autoclave testing at 360°C) first relax during the pre-transition stage. Just before transition, the compressive stress in the monoclinic phase suddenly rises, which is interpreted as indirect evidence of significant tetragonal to monoclinic phase transformation taking place at this stage. TEM studies of pre- and post-transition oxides grown on ZIRLO, a trademark of the Westinghouse Electric Company, have used Fresnel contrast imaging to identify nano-sized pores along the columnar grain boundaries that form a network interconnected once the material goes through transition. The development of porosity during transition was further confirmed by in situ electrochemical impedance spectroscopy (EIS) studies. 3DAP analysis was used to identify a ZrO sub-oxide layer at the metal/oxide interface and to establish its three-dimensional morphology. It was possible to demonstrate that this sub-oxide structure develops with time and changes dramatically around transition. This observation was further confirmed by in situ EIS studies, which also suggest thinning of the sub-oxide/barrier layer around transition. Finally, 3DAP analysis was used to characterise segregation of alloying elements near the metal/oxide interface and to establish that the corroding metal near the interface (in this case ZIRLO) after 100 days at 360°C displays a substantially different chemistry and microstructure compared to the base alloy with Fe segregating to the Zr/ZrO interface.

Characterization of Zirconium Hydrides and Phase Field Approach to a Mesoscopic-Scale Modeling of Their Precipitation

Zirconium alloys are currently used in nuclear power plants where they are submitted to hydrogen pick-up. Hydrogen in solid solution or hydride precipitation can affect the behavior of zirconium alloys during service but also in long term storage and in accidental conditions. Numerical modeling at mesoscopic scale using a “phase field” approach has been launched to describe hydride precipitation and its consequences on the mechanical properties of zirconium alloys. To obtain realistic results, it should take into account an accurate kinetic, thermodynamic, and structural database in order to properly describe hydride nucleation, growth, and coalescence as well as hydride interaction with external stresses. Therefore, an accurate structural characterization was performed on Zircaloy-4 plates and it allowed us to identify a new zirconium hydride phase called ζ. The ζ phase has a trigonal symmetry and is fully coherent with hcp αZr. The consequences of this new zirconium hydride phase on hydride transformation process and stress-reorientation phenomenon are discussed. A first attempt to numerically model the precipitation of this new zirconium hydride phase has been undertaken using the phase field approach.

Understanding Crack Formation at the Metal/Oxide Interface During Corrosion of Zircaloy-4 Using a Simple Mechanical Model

It has been established in previous works that corrosion kinetics in primary water of various zirconium alloys are periodic. Each period is associated with a layer of cracks parallel to the metal-oxide interface. These observations have been made either in autoclave or in pile. This indicates that corrosion processes in autoclave and under irradiation are of similar nature though their absolute kinetics might be different. Taking advantage of this correlation between cracks and corrosion kinetics, the present work aims at identifying the main microstructural parameters controlling cracks appearance in the oxide layer under well-controlled conditions. In order to achieve this, Zircaloy-4 was heat-treated to obtain various metallurgical states (stress-relieved versus recrystallised with different grain sizes) followed by corrosion tests in primary water. The key metallurgical parameters for the various conditions have been analysed (texture, precipitate sizes and grain sizes and distributions) using electron microscopy and synchrotron X-ray diffraction techniques. Corrosion kinetics of the various Zircaloy-4 microstructures are distinct as expected from the literature. Crack morphology in the oxide layer has been analysed and quantified using a dual beam scanning electron microscope/focused ion beam. Crack layers are evident even at small scale of observation. Three dimensional (3D) images of the oxide structure are presented. Cracks observed in this way are typically penny-shaped with a radius of about 100 nm. Near the metal-oxide interface, they are mainly found at the top of metal protrusions in the oxide. The roughness of the metal-oxide interface was measured. It does not exhibit any periodicity. The residual stresses in the oxide layers were measured by high energy (44 keV) synchrotron X-ray diffraction in transmission mode. Large compressive stresses (∼−1 GPa), changing with the metallurgical state and through the oxide scale thickness, were measured. The residual stresses in the oxide layers were measured by high energy (44 keV) synchrotron X-ray diffraction in transmission mode. Large compressive stresses (∼−1 GPa), changing with the metallurgical state and through the oxide scale thickness, were measured. A model of the oxide breaking at the point of transition has been developed. It is based on mechanical considerations and the existence of compressive stress in the oxide layer.

Autoclave study of zirconium alloys with and without hydride rim

Abstract Autoclave corrosion experiments were conducted on a number of zirconium alloys in different heat treatment conditions. The alloys tested in the present work were Zircaloy-4, ZIRLO® (ZIRLO is a registered trademark of Westinghouse Electric Company LLC in the USA and may be registered in other countries throughout the world. All rights reserved. Unauthorised use is strictly prohibited.) and two variants of ZIRLO with significantly lower Sn levels, referred to here as A-0·6Sn and A-0·0Sn. Typical corrosion kinetics with a change from pre- to post-initial transition was observed with ZIRLO and Zircaloy-4 displaying the shortest time to the initial transition after 120–140 days of autoclave exposure, followed by A-0·6Sn materials after 140–260 days. A-0·0Sn materials showed no sign of transition even after 360 days although one sample tested to 540 days had gone through transition. Material in the stress relieved condition generally experienced initial transition earlier than the same alloy in the recrystallised condition. Pretransition samples had a universally black oxide layer, which eventually developed grey patches when transition occurred. Practically, all non-hydrogen charged alloys showed a strong trend towards cubic oxide growth rates. Cathodic hydrogen charging was conducted to simulate end of life condition of cladding tubes, forming a hydride rich rim region at the outer surface of the cladding tubes. Hydrogen charged materials generally experienced accelerated corrosion of different degrees with the exception of recrystallised A-0·0Sn and partially recrystallised A-0·6Sn showing no sign of acceleration. It therefore seems that increasing tin levels has a negative impact on autoclave corrosion behaviour for materials with and without a hydride rich rim. In developing advanced alloys for use in cladding, this effect has been balanced against the benefits that Sn is known to provide in-reactor, including robustness in corrosion behaviour and reduced irradiation growth. It was noted that most materials with a hydride rich rim exhibit parabolic corrosion kinetics with decreased initial weight gain but increased overall weight gain.

Effect of Sn on Corrosion Mechanisms in Advanced Zr-Cladding for Pressurised Water Reactors

The desire to improve the corrosion resistance of Zr cladding material to allow high burnup has resulted in a general trend among fuel manufacturers to develop alloys with reduced levels of Sn. While the detrimental effect of Sn on high temperature aqueous corrosion performance is widely accepted, the reason for it remains unclear. High-Energy synchrotron X-ray diffraction was used to characterise the oxides formed by autoclave exposure on Zr-Sn-Nb alloys with tin concentrations ranging from 0.01 to 0.92 wt.%. The alloys studied included the commercial alloy ZIRLO® and two variants of ZIRLO with significantly lower tin levels, referred to here as A-0.6Sn and A-0.0Sn. The nature of the oxide grown on tube samples from each alloy during autoclave testing at 360°C was investigated by cross-sectional Scanning and Transmission Electron Microscopy (SEM & TEM). Non-destructive synchrotron X-ray diffraction analysis on the oxides revealed that the monoclinic and tetragonal oxide phases display highly compressive in-plane residual stresses with the magnitudes dependent on both phase and alloy. Additional in-situ Synchrotron X-ray diffraction experiments during oxidation at 550°C provided further confirmation of the trends seen for autoclave tested samples and demonstrated the presence of elevated levels of tetragonal phase in the initial stages of oxidation. In-situ and ex-situ measurements demonstrate unambiguously that the amount of tetragonal phase present and, more importantly, the degree of transformation from tetragonal to monoclinic oxide both decrease with decreasing tin levels, suggesting that tin stabilises the tetragonal phase. It is proposed that in Zr-Nb-Sn alloys with low Sn, the tetragonal phase is mainly stabilised by very small grain size and therefore remains stable throughout the corrosion process. By contrast, in alloys with higher tin levels larger, stress stabilised, tetragonal grains can form initially, but then become unstable as the corrosion front progresses inwards and stresses in the existing oxide relax.

A Review of Wear Scar Patterns of Nuclear Power Plant Components

To date, almost all the studies related to component damage have been concerned primarily with dynamic interactions at the interface of contacting components and the subsequent damage due to mechanical wear. Based on the results of examination of a large assortment of photo-micrographs taken from worn reactor components and worn specimens from a broad range of test facilities, it appears that, in many cases, mechanical wear is only a secondary contributing mechanism. With the exception of special cases where severe flow-induced vibration might have occurred, such as in some condensers and primary heat exchangers as well as in the U-bend and inlet regions of some earlier steam generators, resulting in severe component interactions causing substantial wear damage, erosion, corrosion, impacting and perhaps cavitation would seem to be the primary contributing mechanisms.Copyright

Corrosion of M5 in PWRs: Quantification of Li, B, H and Nb in the Oxide Layers Formed Under Different Conditions

Until now, most of the detailed characterizations of the M5 corrosion behaviour were performed under standard PWR operating conditions, under moderate Li content and moderate temperature of the primary coolant. In this study, in addition to these standard conditions, two demanding operating conditions were explored: increased Li chemistry and elevated temperature. The objective is to establish whether these more demanding conditions have an impact on the structure of the oxide layers formed, on Nb, Li and B contents in these layers and on Hydrogen pickup of the cladding. The structure of oxide layers was studied by microscopy, the Nb content and distribution by Electron Probe Micro Analysis, the Li and B contents and distributions by Nuclear Reaction Analysis and the hydrogen pickup by gas extraction. It was observed that the stability of the corrosion behaviour of M5 is not affected by increased Li or elevated temperature conditions. The hydrogen pickup fraction of M5 is not modified by increased Li conditions or by irradiation temperature with measured contents (

Understanding of Corrosion Mechanisms after Irradiation: Effect of Ion Irradiation of the Oxide Layers on the Corrosion Rate of M5

Irradiation damage in fuel cladding material is mainly caused by the neutron flux that results from fission reactions occurring in the fuel. To avoid the constraints inherent in handling radioactive material, the irradiation effects on the corrosion resistance of zirconium alloys can be studied by irradiating the materials with ions. We performed an original experiment using ion irradiation to more specifically study the influence of irradiation damage in the oxide on the corrosion rate of M5®. It has been established that irradiation with a 1.3-MeV helium ion at a fluence of 1017 cm−2 results in significant modifications of oxide properties, oxygen diffusion flux, and oxidation kinetics, as evidenced by Raman spectroscopy, secondary ion mass spectrometry (SIMS) analyses, and measurements of mass gains. A newly identified Raman vibration band at 712 cm−1 was linked to the presence of irradiation defects and allowed the evolution of their concentrations to be followed. The oxygen diffusion flux was significantly reduced after irradiation partly due to a surface concentration decrease of oxygen. The defects remained present in the oxide after 100 days of annealing in pressurized water reactor (PWR) conditions and were thus very stable in PWR conditions, which probably means that these defects would be stable in the reactor. According to the kinetics and in agreement with the results obtained by SIMS analyses, the oxidation rate was significantly reduced after ion irradiation, and this effect remained beyond 100 days in agreement with the high stability of irradiation defects in PWR conditions. An original model described quite well the oxidation kinetic results.

Comparison between tribocorrosion mechanisms of Stellite 6 and Zircaloy 4 in LiOH-H3BO3 solutions

Tribocorrosion mechanisms of Stellite 6 and Zircaloy 4 alloys were studied by means of tribocorrosion tests carried out in conditions of unidirectional sliding friction in a solution of boric acid and lithium hydroxide, with same chemical composition as water in nuclear Pressurized Water Reactors. With Stellite 6, a “soft wear” process is obtained, controlled by mechanical removal and subsequent restoration of a very thin passive film. With Zircaloy 4, in the same tribological conditions, a major influence of abrasion by zirconia particles, pulled out from the zirconia surface layer, was observed. These major differences in the tribocorrosion mechanisms explain the differences found in wear laws.