Microstructure and mechanical performance of cold spray Cr coatings

Cold spray deposition has emerged as a promising method for applying protective coatings in the nuclear in-
dustry, particularly for enhancing the accident tolerance of fuel assemblies. In this process, helium gas is often
used to propel solid powder particles towards the target substrate, however, nitrogen gas is also considered due
to its significantly lower cost. In this study, we investigate the influence of nitrogen and helium gas as propellants
on the properties and microstructure of pure chromium (Cr) coatings on zirconium (Zr) alloy cladding tubes.
Employing Scanning Electron Microscopy (SEM) and electron and x-ray diffraction techniques (EBSD, XRD), we
explore the structural characteristics of the coatings. Additionally, in-situ SEM tensile testing at room tempera-
ture, coupled with Digital Image Correlation (DIC), is utilized to assess the coating cracking behaviour. Our
findings reveal distinct differences in coating morphology and residual stress between nitrogen and helium
propelled Cr coatings. The nitrogen-propelled coating exhibits a more porous structure with smoother coating/
substrate interfaces and lower compressive residual stress compared to the helium-propelled one. This results in
earlier strain-induced crack initiation and higher crack density at lower strains (0.5–2%). However, at higher
strains (2–5%), both coatings demonstrate identical crack saturation densities (saturated number of cracks per
unit length), accompanied by similar crack toughening mechanisms and evidence of shear strain bands at
intercrack regions, indicative of plasticity onset.