Corrosion-resistant coatings in molten salts suggested by computational phase-stability diagrams
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Engineering topics
Publications and source records attributed to Zhang, Jinsuo.
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This paper applied electrochemical methods to explore the corrosion mechanisms of metals and steels in purified molten chloride salt, especially under conditions dominated by cathodic diffusion limitations.
Here the present study determines the equilibrium concentration of OH- in molten MgCl 2 -NaCl-KCl salts and measures the kinetic properties data of OH- (diffusion coefficient, exchange current density, charge transfer coefficient, limiting current density, and standard rate constant) accordingly at different temperatures. The equilibrium concentration of OH- descends as the temperature increases, which ranges from 4.11 to 2.84 × 10 -6 mol cm -3 in the temperature range of 600 °C–800 °C. The diffusion coefficient follows Arrhenius law with a value between 2.46 and 4.48 × 10 -4 cm 2 s -1 . The exchange and limit current densities, and standard rate constant increase with temperature. The calculated standard rate constant κ 0 follows Arrhenius law, which is in the range from 1.23 to 2.50 × 10 -4 cm s -1 . The measured charge transfer coefficient is independent of temperature, which validates the present measurements.
Antimony is being investigated as a potential additive to metallic fuel to control fuel-cladding chemical interactions (FCCI). The most detrimental elements involved in FCCI are fission product lanthanides, leading to brittle intermetallics and low melting eutectic phases. Previous investigations of Sb as an additive focused on U-10Zr, in wt. %, as the fuel. The current investigation expands that to include Pu in the fuel. Here, two alloys, U-20Pu-10Zr-4Sb and U-20Pu-10Zr-4Sb-4Ln (wt. %, Ln=53Nd-25Ce-16Pr-6La) have been investigated using scanning electron microscopy (SEM) and transmission electron microscopy (TEM) to characterize the fuel as-cast microstructure and the microstructure after introduction of lanthanides. Sb reacts with Zr initially, forming Zr 2 Sb and Zr 5 Sb 3 , with as much as 20 at. % interstitial Pu present. In the presence of lanthanides, Sb forms Ln 4 Sb 3 with the lanthanides, containing ~14 at. % Pu. The Pu is substitutional for the lanthanides in the crystal lattice.
This research article explores the potential of optical fibers as sensors, highlighting their ability to measure various parameters such as temperature, pressure, stress, and radiation dose. The study focuses on investigating the material compatibility of optical fibers in challenging sensing environments like Gen II/II+ and advance nuclear reactors, as well as concentrated solar power (CSP) plants. Material compatibility tests were conducted to determine the feasibility of using fluorine and germanium optical fiber sensors in these environments. The study found that raw fibers were corrosion-resistant to lead bismuth eutectic at 600 °C, regardless of the coating. In molten salt environments, raw fibers were incompatible with FLiNaK but showed corrosion resistance to MgCl₂-NaCl-KCl. However, the survivability of raw fiber optics improved with a gold coating in FLiNaK. Raw fiber optics were found to be incompatible in high-temperature steam at 1200 °C and in a pressurized water reactor (PWR) at 300 °C.
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The KAERI advanced spent fuel conditioning process (ACP) process is a critical component of the US- South Korean nuclear cooperation and the following “123 Agreement.” Its development has received considerable attention in both countries. The ACP is an electrochemical processing (pyroprocessing) that recycles over 96% of the used nuclear fuel (UNF). It is also intrinsically proliferation-resistant in theory. In normal operation, the U/TRU product is very hot radiologically. In addition, the Cm provides a high level of spontaneous neutrons, making the product unsuitable for weapon use. However, as pointed in some study, “the need for safeguards to protect against the diversion and misuse of separated plutonium applies essentially equally to all grades of plutonium.” As pointed by many studies, the well-established traditional Nuclear Material Accounting (NMA) approach cannot be directly applied to electrochemical processing because of the lack of an input accountability tank, the non-continuous material flow, and the unsatisfactory level of confidence in sampling methods. Therefore, nuclear safeguards remain a grand challenge in the developing of commercial electrochemical separations facilities, especially around the heart of such facilities, the electrorefiner (ER) systems. In contrast to NMA data, process monitoring (PM) data is normally an indirect measurement of the SNM and is acquired much more frequently. In a broad sense, PM includes monitoring by various types of equipment, e.g. radiation detectors, cameras, voltage, current sensors. Because it is already being collected by the operator, the additional cost to safeguards is low. It has long been believed that PM data can supplement NMA data and help improve safeguards, although the benefits are hard to quantify. The U.S. DOE’s Material Protection, Accounting, and Control Technology (MPACT) campaign has made substantial investments into innovative PM sensor technology and predictive model development for real- or near real-time measurement and prediction of molten salt density and level, salt composition and actinide concentration especially Pu, the cell voltage, and the cell current to supplement traditional NMA. For aqueous-based reprocessing facilities, it is reported that PM, integrated with traditional NMA, have a high detection probability for specific diversions. For electrochemical reprocessing, preliminary studies have shown that PM data can support traditional NMA in various ways by providing a basis to estimate some of the in-processing nuclear material inventories. Despite early success, further studies on fusion of PM data and NMA data are still needed, which is the goal of this proposed work.
The goal of this research is to fill the knowledge gaps of salt properties and gain a fundamental understanding of corrosion mechanisms, thereby to guiding material selections of salts and containment materials. The proposed research is focused on building unique cross-cutting research capabilities that can perform research and analysis relevant to the following three research topics important for Generation 3 Concentrating Solar Power Systems: (1) Material characterization including investigations of fluid thermophysical properties and stability, (2) Durability testing of containment materials, and (3) Corrosion behavior characterization relative to levels of known contaminants (e.g., water and oxygen) in Heat Transfer Fluid (HTF).
We report quaternary fuel alloys containing U, Nb/Mo, Ti, and Zr are proposed as fuel candidates for sodium-cooled fast reactors (SFRs). In this work, two Nb-bearing alloys, i.e., U-NT5Z (U-2.5Nb-2.5Ti-5.0Zr in wt%) and U-NT7Z (U-1.5Nb-1.5Ti-7.0Zr in wt%), and two Mo-bearing alloys, i.e., U-MT5Z (U-2.5Mo-2.5Ti-5.0Zr in wt%) and U-MT7Z (U-1.5Mo-1.5Ti-7.0Zr in wt%) were characterized and compared. The characterization techniques were differential scanning calorimetry (DSC), X-ray powder diffraction (XRD), and scanning electron microscopy/energy dispersive X-ray spectroscopy (SEM/EDS). DSC was performed to obtain the transition behaviors, and XRD and SEM/EDS were applied for phase identification. The results were combined to obtain the solid-state phase transitions between 500 °C and 850 °C for the alloys. It is found that the Nb-bearing alloys comprise similar phase transition behaviors as the Mo-bearing alloys. The phase transitions in U-NT5Z are a →γ at 608 °C and U 2 Ti → γ at 627 °C, which are ~40 °C higher than that of U-MT5Z. The phase transition in U-NT7Z is a → γ at 645 °C, and is 23 °C higher than that of U-MT7Z.
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This study focuses on the solid-state phase transitions of two quaternary fuel alloys for fast reactors: U-1.5Mo-1.5Ti-7.0Zr (U-MT7Z) and U-2.5Mo-2.5Ti-5.0Zr (U-MT5Z). Here, the phase transitions were determined by differential scanning calorimetry (DSC), X-ray powder diffraction (XRD), and scanning electron microscopy/energy dispersive X-ray spectroscopy (SEM/EDS). To identify the high temperature phases, the alloys were annealed at 873K, 948K, 1023K, and 1123K (all under 72 hours). Combining those characterizations, the phase transitions are determined. In U-MT7Z, there is one phase transition observed, and it is ascribed to α + U 2 Ti → γ transition. In U-MT5Z, two transitions are found. The first transition is α → γ, while the second is U 2 Ti → γ. The γ phase onset temperature of U-MT5Z is lower than that of U-MT7Z due to the higher Mo content.
Here, the fundamental kinetic parameters of corrosion product ions (Fe, Ni and Cr ions) are of significant importance to understand the corrosion mechanisms of the structural materials in the molten salts. In the present study, the fundamental data of Fe 2+ , Ni 2+ , Cr 2+ and Cr 3+ (diffusion coefficient D, exchange current density i 0 , charge transfer coefficient α, limiting current density i L and standard rate constant k0) were measured at different concentrations (1.53 × 10 –6 –7.48 × 10 –4 mol cm –3 ) and temperatures (600 °C–800 °C). The values of D are independent of concentrations and follow Arrhenius law with temperature, which descend in the order of D Cr 2+ > D Fe 2+ > D Cr 3+ > D Ni 2+ with values ranging from 0.94 × 10 –5 to 3.31 × 10 –5 cm 2 s –1 . Both i 0 and k 0 depend on the temperatures, which also follow Arrhenius law.
University research is a strong focus of the Office of Nuclear Energy within the Department of Energy. This research complements existing work in the various program areas and provides support and training for students entering the field. Four university projects have provided support to the Material Protection Accounting and Controls Technologies (MPACT) 2020 milestone focused on safeguards for electrochemical processing facilities. The University of Tennessee Knoxville has examined data fusion of NDA measurements such as Hybrid K-Edge Densitometry and Cyclic Voltammetry. Oregon State University and Virginia Polytechnic Institute have examined the integration of accountancy data with process monitoring data for safeguards. The Ohio State University and the University of Utah have developed a Ni-Pt SiC Schottky diode capable of high temperature alpha spectroscopy for actinide detection of molten salts. Finally, the University of Colorado has developed a key enabling technology for the use of Microcalorimetry.
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In this study, a graphite rotating disc electrode was successfully designed and applied to conduct electrochemical measurements under flow conditions in molten LiCl-KCl at 773 K. The concentration and diffusion coefficients of Eu 3+ and Eu 2+ in molten salt were quantitatively measured with this electrode by applying in situ cyclic voltammetry and chronoamperometry techniques. The initial concentration ratio of Eu 3+ /Eu 2+ in LiCl-KCl-0.5 wt% EuCl 3 was calculated to be 2.37. The calculated diffusion coefficients of Eu 3+ and Eu 2+ in the salt were 9.31 ± 0.06 × 10 -5 cm 2 s -1 and 9.65 ± 0.6 × 10 -5 cm 2 s -1 , respectively. A decrease of the diffusion coefficient of Eu 3+ and Eu 2+ was observed at a higher concentration of EuCl 3 , which implies the enhanced Eu-Eu ion interaction. This electrode design is expected to be utilized for the concentration measurement of multivalent ions in a flowing molten salt.
FeCrSi alloys have been proposed as alternatives to FeCrAl alloys for accident-tolerant fuel cladding in light water reactors. Experiments on the oxidation resistance of three Fe-Cr-2Si alloys in high-temperature steam, with 12, 16, and 20 wt. % Cr, show that ≥16 % Cr is sufficient to form a thin, passivating, binary oxide layer. Additionally, at 1200 °C, only Cr 2 O 3 and SiO 2 form on Fe 16 Cr 2 Si and Fe 20 Cr 2 Si, while additional ternary Fe oxides form on Fe 12 Cr 2 Si. Decohesion and spalling of oxide were observed on Fe-Cr-Si alloys exposed to steam at 900 °C and above. Fe 20 Cr 2 Si exhibits the best oxidation resistance of the three in high-temperature steam.
The current study focuses on characterization of two potential fuel alloys for sodium-cooled fast reactors: U-2.5Mo-2.5Ti-5.0Zr (U-MT5Z) and U-1.5Mo-1.5Ti-7.0Zr (U-MT7Z) in wt. %. As-cast alloys and annealed (600°C, 500h) alloys are studied by X-ray powder diffraction (XRD) for their bulk structures, and scanning electron microscopy / energy dispersive X-Ray spectroscopy (SEM/EDS) for their microstructures and phase constituents. For as-cast alloys, the XRD results show that U-MT5Z mainly contains γ, while U-MT7Z alloy contains a. In both alloys, there are three phases indicated by EDS, a U-rich phase, secondary phase, and Zr-rich phase. Further, the elemental compositions varied in different phases and in different alloys. After annealing, both alloys exhibit the structures of α-U and U 2 Ti according to XRD. The EDS results suggest there are five phases found in both alloys.