Semi-integral LOCA testing of Cr-coated Optimized ZIRLOTM claddings

Chromium (Cr)-coatings on zirconium-(Zr) based claddings have emerged as a promising short-term solution to enhance the accident tolerance of fuel assemblies in pressurised water reactors (PWRs) during loss-of-coolant accidents (LOCAs). In this study, we tested a large number (36 rods in total, each 30cm long) of uncoated and Cr-coated Optimized ZIRLOTM claddings under thermomechanical conditions that closely resemble a real LOCA. A unique experimental apparatus was employed to integrate multiple LOCA effects into a single test sequence, enabling a more accurate prediction of the performance of Cr-coatings and degradation mechanisms of the coated claddings. More specifically, the test sequence included: i) thermal ramping from 350–1200°C under varying internal pressures and heating rates in flowing steam; ii) isothermal steam oxidation at 1200°C for different durations; ii) cooling to 700°C followed by water quenching to 135°C; iv) partial-axial constraint at 135°C with load hold of 540N for 20s. Various characterisation techniques, including optical and scanning electron microscopy (SEM), 3D laser scanning, electron backscattered diffraction (EBSD), hardness testing and hydrogen analysis, were used to characterise the post-LOCA cladding microstructures. We found that Cr-coatings increased the burst temperature of uncoated claddings by ∼ 25–150°C and reduced the strain-to-burst and cladding deformation within 20 mm away from the burst opening. The magnitude of these improvements depended on the initial testing conditions and were more pronounced for the helium-propelled cold spray (HCS) coating, while less pronounced for the nitrogen-propelled CS (NCS) and physical vapour deposition (PVD) coatings. Additionally, we found that Cr-coatings increased the time threshold before significant cladding embrittlement by ∼100–555s compared to uncoated claddings. Finally, we concluded that when multiple LOCA effects are considered, predictions of additional coping time during a LOCA provided by the Cr-coatings are more conservative compared to single-factor tests.