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Chromium-based coatings and diffusion barriers for accident-tolerant fuel applications.

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Title: Chromium-based coatings and diffusion barriers for accident-tolerant fuel applications.
Authors: Song, Hailing1 (AUTHOR), Ma, Zhen1 (AUTHOR), Song, Peng1,2,3 (AUTHOR), Li, Qing1,2,3 (AUTHOR) qinglikm@163.com
Source: Journal of Materials Science. Feb2026, Vol. 61 Issue 8, p5032-5066. 35p.
Subjects: Diffusion barriers, Chromium alloys, Heat resistant alloys, Materials testing, Ceramic engineering, Fukushima Daiichi Nuclear Power Plant (Japan), Oxidation, Zirconium alloys
Abstract: The 2011 Fukushima accident exposed critical safety limitations in conventional UO2–Zr fuel systems, accelerating the development of accident-tolerant fuel (ATF) technologies. Chromium coatings on zirconium alloy cladding emerge as the most promising near-term solution, offering superior high-temperature oxidation resistance through protective Cr2O3 scale formation effective up to 1200 °C. However, critical challenges remain from Cr–Zr interdiffusion above the 1332 °C eutectic temperature, driving the development of advanced diffusion barriers including ceramic systems (ZrO2, CrN), metallic interlayers (Mo, Nb, Ta, W), and multilayer architectures. Systematic evaluation reveals material-specific trade-offs: ceramic barriers (ZrO2, CrN) demonstrate effectiveness up to 1200–1300 °C but encounter dissolution and phase transformation limitations; refractory metal barriers exhibit temperature-dependent performance, with Mo systems effective to 1300–1400 °C, Ta barriers to 1400–1500 °C approaching benchmark performance, and W-based systems exceeding 1500 °C; composite FeCrAl architectures provide intermediate capability (1200–1350 °C) with enhanced oxidation resistance but face thermal expansion mismatch challenges and require enhancement beyond 1000 °C. Future priorities include mechanistic lifetime modeling, in situ characterization, and processing standardization to enable commercial deployment with quantified safety margins. [ABSTRACT FROM AUTHOR]
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Database: Engineering Source
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Abstract:The 2011 Fukushima accident exposed critical safety limitations in conventional UO2–Zr fuel systems, accelerating the development of accident-tolerant fuel (ATF) technologies. Chromium coatings on zirconium alloy cladding emerge as the most promising near-term solution, offering superior high-temperature oxidation resistance through protective Cr2O3 scale formation effective up to 1200 °C. However, critical challenges remain from Cr–Zr interdiffusion above the 1332 °C eutectic temperature, driving the development of advanced diffusion barriers including ceramic systems (ZrO2, CrN), metallic interlayers (Mo, Nb, Ta, W), and multilayer architectures. Systematic evaluation reveals material-specific trade-offs: ceramic barriers (ZrO2, CrN) demonstrate effectiveness up to 1200–1300 °C but encounter dissolution and phase transformation limitations; refractory metal barriers exhibit temperature-dependent performance, with Mo systems effective to 1300–1400 °C, Ta barriers to 1400–1500 °C approaching benchmark performance, and W-based systems exceeding 1500 °C; composite FeCrAl architectures provide intermediate capability (1200–1350 °C) with enhanced oxidation resistance but face thermal expansion mismatch challenges and require enhancement beyond 1000 °C. Future priorities include mechanistic lifetime modeling, in situ characterization, and processing standardization to enable commercial deployment with quantified safety margins. [ABSTRACT FROM AUTHOR]
ISSN:00222461
DOI:10.1007/s10853-026-12163-7