High-temperature oxidation and hydrothermal corrosion of textured Cr2AlC-based coatings on zirconium alloy fuel cladding

Abstract Alumina-forming MAX phase coatings reveal great potential for accident tolerant fuel (ATF) cladding applications due to their favorable physical and mechanical properties and excellent high-temperature oxidation resistance. The feasibility of the Cr2AlC MAX phase as protective coating on zirconium-alloy fuel claddings was explored focusing on its high-temperature oxidation resistance in steam and hydrothermal corrosion performance in autoclave. Single-phase and basal-plane textured Cr2AlC coatings (~6 μm thick) were synthesized on Zircaloy-4 substrate by thermal annealing of specifically designed, magnetron-sputtered Cr/C/Al elemental multilayers at 550 °C for 10 min. Additionally, a second Cr/Cr2AlC bilayer coating design was fabricated aiming to eliminate potential rapid hydrothermal dissolution of Al during normal operating conditions. Micro-cracking appeared on both annealed coatings owing to thermal expansion differences between coating layer and substrate. Growth of an adherent and dense α-Al2O3 scale during high-temperature oxidation in steam and of a thin passivating Cr2O3 layer during hydrothermal corrosion in an autoclave imply excellent combined oxidation and corrosion resistance of the textured Cr2AlC coatings on Zircaloy-4. A self-healing capability via growth of alumina filling the micro-crack (annealing-induced) gaps was observed during high-temperature oxidation. However, partial delamination was seen for both coatings after short autoclave exposure and their mechanical properties (fracture toughness and adhesion strength) need further enhancement. Overall, tailored Cr2AlC-based (multilayered) coatings can be attractive candidates as potential type of coated ATF claddings.