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中国材料进展[ISSN:1674-3962/CN:61-1473/TG]

卷:

45

期数:

2026年11

页码:

010-19

栏目:

出版日期:

2026-10-31

文章信息/Info

Title:

Cr and FeCrAl Accident-Tolerant Coatings on Zirconium Alloy Cladding:Preparation, Service Performance and Protective Mechanisms

作者:

刘蓝忆; 胡锐文; 董子烨; 赵亚欢; 沈朝*; 曾小勤

上海交通大学材料科学与工程学院，上海，200240

Author(s):

LIU Lanyi;  HU Ruiwen;  DONG Ziye;  ZHAO Yahuan;  SHEN Zhao;  ZENG Xiaoqin

School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China

关键词:

锆合金包壳; Cr涂层; FeCrAl涂层; 高温水腐蚀; 高温蒸汽氧化; 微动磨损

Keywords:

zirconium alloy cladding;  Cr coating;  FeCrAl coating;  high-temperature water corrosion;  steam oxidation;  fretting wear

文献标志码:

A

摘要:

福岛核事故后，耐事故燃料（Accident Tolerant Fuel, ATF）被认为是提高轻水堆设计基准事故和超设计基准事故安全裕量的重要技术方向。作为兼顾工程可实现性与现役燃料组件兼容性的近中期方案，在锆合金包壳表面构筑Cr或FeCrAl防护涂层，可在基本保持包壳几何尺寸和燃料设计体系不变的前提下，显著改善包壳的高温蒸汽抗氧化、高温高压水耐腐蚀和格架微动耐磨性能。本文围绕涂层制备工艺、力学完整性、PWR正常运行水化学环境下的腐蚀与微动磨损，以及LOCA/严重事故工况下的高温氧化和界面失效行为，系统综述Cr涂层与FeCrAl涂层的研究进展，并重点阐明“制备工艺—微观组织—服役性能—失效机制”之间的内在关联。结果表明，Cr涂层具有热膨胀匹配较好、制备路线相对成熟、堆内示范进展较快等优势，但仍受含氧水环境中Cr2O3溶解、低温脆性开裂、事故高温下Cr-Zr互扩散和涂层厚度窗口的制约；FeCrAl涂层依托Fe氧化物、富Cr尖晶石以及在适宜成分和氧化条件下形成的含Al氧化物构建多级保护，并表现出较好的化学稳定性和裂纹自密封潜力。对于微米级FeCrAl涂层，Al含量和界面互扩散会影响保护膜的持续再生，同时Fe-Zr反应、辐照效应和堆内长期行为仍需进一步评估。未来应通过致密化与低缺陷制备、晶界和织构调控、扩散阻挡层、多层/梯度复合结构以及标准化堆内外评价体系，推动涂层型ATF包壳从实验室性能验证向工程许可与商业应用过渡。

Abstract:

After the Fukushima accident, accident-tolerant fuel (ATF) has been regarded as a key approach for increasing the safety margins of light-water reactors under design-basis and beyond-design-basis accident conditions. Among the near- and medium-term concepts that retain compatibility with existing fuel-assembly designs, Cr and FeCrAl coatings on Zr-alloy cladding can markedly improve high-temperature steam oxidation resistance, high-temperature aqueous corrosion resistance and grid-to-rod fretting-wear performance while largely preserving the geometry of current cladding tubes. This review summarizes recent progress in coating preparation, mechanical integrity,corrosion and fretting wear in PWR water chemistry, and high-temperature oxidation and interfacial degradation under LOCA or severe-accident conditions. Particular emphasis is placed on the correlations among processing, microstructure, service performance and failure mechanisms. Cr coatings benefit from favorable thermal-expansion compatibility, relatively mature fabrication routes and rapid in-pile demonstration, but their reliability is still constrained by Cr2O3 dissolution in oxygenated water, brittle cracking at low temperature, Cr-Zr interdiffusion at accident temperatures and the allowable coating-thickness window. FeCrAl coatings rely on Fe-rich oxides, Cr-rich spinels and Al-containing oxides formed under appropriate compositional and oxidation conditions, providing multilevel protection together with promising chemical stability and crack self-sealing. For micron-scale FeCrAl coatings, limited Al inventory and interfacial interdiffusion affect long-term scale regeneration, while Fe–Zr reactions, irradiation effects and long-term in-pile behavior remain to be clarified. FeCrAl coatings provide hierarchical protection through Fe-rich oxides, Cr-rich spinels and Al2O3, showing promising chemical stability and crack self-sealing capability;nevertheless,neutron economy, Fe-Zr eutectic reactions, irradiation hardening and insufficient long-term in-pile databases remain critical barriers. Future work should focus on dense and low-defect manufacturing, grain-boundary and texture engineering, diffusion-barrier interlayers,multilayer/graded coating architectures, and standardized out-of-pile/in-pile qualification methodologies to accelerate the transition of coated ATF claddings from laboratory validation to licensing and commercial deployment.

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更新日期/Last Update: 2026-09-28