Zircaloy | EPFL Graph Search

Zircaloy (de l'anglais Zirconium et « alloy », alliage) est un nom générique et de marque donné à un groupe d'alliages de zirconium (solutions solides). thumb|« Crayon » constitué d'un tube de zircaloy destiné à recevoir un empilement de pastilles d'uranium, élément de base d'un des assemblages qui seront insérés dans le réacteur nucléaire d'une centrale nucléaire. Le Zircaloy est utilisé dans l'industrie chimique pour ses remarquables propriétés physico-chimiques. Ses matériaux constitutifs sont abondants, mais la purification du zirconium est coûteuse. Ces alliages sont utilisés surtout dans l'industrie nucléaire (dans les « réacteurs à eau » notamment), en raison de leurs caractéristiques de transparence neutronique (le zirconium a une très faible section efficace d'absorption des neutrons thermiques). Ils forment le gainage des crayons combustibles, qui sont la première barrière de confinement, la seconde étant l'enveloppe du réacteur et du circuit primaire. Le refroidiss

Delayed Hydride Cracking in Irradiated and Unirradiated Zircaloy-2 Cladding

Aaron William Colldeweih

Zirconium alloys used in the nuclear industry are exposed to extreme conditions undergoing high levels of irradiation damage and corrosion. Zircaloy-2 is used as nuclear fuel cladding in boiling water reactors and for the encapsulation of the spallation target in the neutron source SINQ at the Paul Scherrer Institute. As a result of oxidation, hydrogen is produced and partially taken up into the zirconium matrix. As the hydrogen reaches the solubility limit, it precipitates in the form of a zirconium hydride. A number of deleterious effects of hydrides have been extensively studied, including the embrittlement of the material and a unique cracking phenomenon, namely delayed hydride cracking (DHC). DHC occurs as hydrogen in solid solution diffuses towards locations of higher tensile stress, where it subsequently precipitates as the local solvus limit is reached. Once the hydride grows to a critical size, it fractures, which can continue to propagate in repeated steps by the same mechanism.Several studies have been performed in order to understand properties of DHC based on parameters like, alloy type, cracking temperature, hydrogen content, and cracking direction. The most important mechanical properties include the fracture toughness and cracking velocity, which governs the material failure conditions. Crystallographic properties have been investigated in order to understand how complex hydride precipitation develops within the context of DHC conditions. In this project, radial DHC is explored in irradiated and unirradiated thin-walled Zircaloy-2 nuclear fuel cladding with and without an inner liner, in addition to spallation target rod material. A unique three-point bending test, applicable also for irradiated samples in the hotlab, was developed to induce a consistent radially propagating outside-in crack. Results have provided insight into the effects of the inner liner on cracking velocity, showing correlations with the hydrogen depletion. The combined DHC and creep mechanisms, which cannot be decoupled, is coined as âcreep-delayed hydride crackingâ. As the initiating conditions for DHC are of great technical importance, the threshold stress intensity factor has been investigated, under ideal DHC conditions, where a minimum value occurs around 6 MPaâm. Quantitative analysis of the hydrogen distribution around the tip of an arrested DHC crack tip has been performed with neutron radiography at the SINQ. Trends show that the hydrogen concentration around the crack tip increases with temperature resulting likely from the larger hydrogen diffusion, and that the liner reduces the hydrogen available for DHC. Crystallographic analysis has provided insight on the hydride phases responsible for DHC with synchrotron micro X-ray diffraction, performed at the Swiss Light Source at PSI. The results directly suggest that the Î³-hydride is a stable phase precipitated at low temperatures. Testing of irradiated material provided insight into the crack initiation of DHC as a result of the strongly irregular outer surface generated from the oxidation. The propagation pattern is highly irregular compared to the unirradiated material due to the embrittled nature of the cladding from irradiation damage.

EPFL2022

Microstructure of single crystal Ni-based superalloys during blade manufacturing process and creep deformation

Stéphane Pierret

The aim of the thesis is to obtain more understanding about the influence of plastic deformation on the microstructural changes observed in single crystal (SX) Ni-based superalloys using diffraction techniques. This work was organised around two main problematics: (1) rafting in turbine blades after the manufacturing process and (2) rafting and mosaicity evolution in two SX alloys with different composition during creep deformation. SX Ni-based superalloys are first choice materials for turbine blade application in land-based gas turbines and aero-engines. Superior mechanical properties of these materials at high temperatures are achieved due to the optimisation of the alloying composition and the microstructure. SX Ni-based superalloy turbine blades solidify by dendritic solidification with dendrites aligned along the directions of lowest Young modulus (interdendritic spacing around 300μm). At the end of the manufacturing process, the microstructure consists of high volume fraction of cubic γ’ precipitates (around 500nm) coherently embedded in the γ matrix. However specific parts of engine-ready turbine blades exhibit directionally coarsened γ’ precipitates in a preferred direction (rafting) without the influence of an applied load. It is of prime importance to understand the origin of rafting prior to the introduction of the blades in the engine since rafting can alter the mechanical properties of the alloy. Chemical segregations and the introduction of plastic deformation prior to thermal treatments were identified as potential driving force for rafting during load-free high temperature annealing. Most of the SX Ni-based superalloys used in the current blade production in Alstom contain significant amount of refractory elements which are expensive and increase the density of the alloy. To answer the demand of cheaper and lighter components, Alstom launched a development program to design novel SX superalloys. One of these projects led to the production of a Re-free superalloy, so-called MD2. Extensive mechanical investigations on MD2 are on-going and compared to the behaviour of the MK4HC alloy (3wt% Re) currently used in turbine blade production. One of the major differences in terms of mechanical properties between Re-containing and Re-free SX alloys is the faster kinetics of coarsening and rafting during creep deformation at high temperature in the latter alloys. It prevented so far their application in the hottest areas in gas turbines. It is therefore of utmost importance to acquire more knowledge about the mechanisms associated with the microstructure evolution during creep of the new MD2 SX alloy in comparison with the MK4HC alloy. The evolution of the lattice parameter misfit in different directions with respect to the applied load during creep deformation was associated with the evolution of the microstructure from cubic to elongated γ’ precipitates It could be shown that rafting occurs after the cooling stage following the solution heat treatment (SHT) during the manufacturing of the blade with investigations of the microstructure. The influence of chemical segregations on rafting was excluded with the investigation of the blade alloy composition in different parts of the blade cooled from the SHT and diffraction measurements in stress-relieved combs prepared from the same blade. The formation of a rafted microstructure during the manufacturing process was associated with the formation of plastic strains during cooling after the SHT. This was confirmed after gathering results from investigations of the microstructure, simulation of the cooling stage and neutron diffraction measurements on the blade. The investigations of the microstructure performed on the engine-ready blade revealed an inversion of the γ’ raft orientation below (parallel to [001]) and above the platform of the blade (perpendicular to [001]). This was attributed to an inversion of the sign of residual strain between the previously mentioned positions as revealed by neutron diffraction measurements performed along the airfoil of the blade cooled after the SHT. Microscopy also showed that the rafted microstructure was more pronounced below the platform (long γ’ rafts) than above the platform (shorter γ’ rafts with retained cubic precipitates). The concept of the threshold plastic strain necessary to induce rafting during annealing subsequent to plastic deformation was used to describe the difference in rafted microstructure. It is suggested that plastic strains largely exceed the threshold below the platform leading to fully formed rafted microstructure. On the other side, plastic strains of the order to the threshold strain are suggested above the platform in order to explain the partially formed rafted microstructure Neutron diffraction measurements revealed that the lattice parameter misfit was larger in the MK4HC than in the MD2 alloy at 20°C in the unloaded state. The larger misfit in the MK4HC alloy was attributed to the larger concentration of elements dissolving in the γ phase and to the presence of Re. During creep deformation, coherency stresses are relieved at the γ/γ’ interface in the γ channels perpendicular to the applied load by dislocations. On the other hand, dislocations increase the internal stress at the γ/γ’ interface in the γ channels parallel to the applied load. This leads to the rafting of the γ’ precipitates perpendicular to the applied load. This was observed in the MK4HC. The absence of clear misfit evolution in the MD2 alloy was attributed to the anomalous microstructure at the beginning of the creep deformation. The mosaicity of the MK4HC and MD2 alloys revealed crystallographic misorientation between neighbouring dendrites up to 0.5°. The misorientation was associated with the presence of dislocations in the regions between the dendrites formed during the dendritic solidification of the alloys from existing work. It was shown that the composition of the SX alloys and short periods at high temperature in the unloaded state had only little influence on the misorientation between neighbouring dendrites. Upon creep loading to 180MPa, the mosaicity markedly changed in the two SX alloys independent of the creep temperature. In particular, the number of single misoriented domains measured by X-ray diffraction decreased. This was attributed to the fast propagation of the dislocations present in the interdendritic structure inducing a rotation of the individual dendrites. During creep deformation, the mosaicity increased as visible from the broadening of the maximum spread in misorientation. The formation of inhomogeneous plastic strain fields in the γ/γ’ microstructure is believed to create new mosaic blocks in the dendritic structure of the alloys leading to the observed broadening of the mosaicity. The influence of plastic deformation on the evolution of the mosaicity was demonstrated. The mosaicity significantly changed during creep of the MD2 at 1050°C/180MPa and 1000°C/180MPa whereas no significant evolution could be measured during creep at 950°C/180MPa. This was attributed to a temperature dependence of the yield strength of the MD2 alloy. It therefore induces difference in dislocation propagation at 950°C compared to 1050°C and 1000°C which retards the broadening of the mosaicity during creep at 950°C. Furthermore, the mosaicity formed during creep deformation was retained upon unloading and cooling of the SX samples to room temperature.

EPFL2012

Etude de l'effet du brassage électromagnétique sur les microstructures d'alliages cuivreux

Thomas Campanella

In order to eliminate internal and surface defects, which appear in the ingots during continuous casting of metallic alloys, homogeneous and fine structures are often required. Therefore, when the adjunction of inoculant substances is not possible, the electromagnetic stirring (EMS) process is used during solidification. It consists to create convective mouvements in the liquid part of the casting, by the action of an electromagnetic field. A fine equiaxed grain structure can then be observed. The main goal of this research is to study the effect of the EMS process on grain structures for two industrial copper-base alloys : C97 (Cu-1%Ni-1%Pb-0.2%P) and BZ4 (Cu-4%Zn- 4%Sn-4%Pb). In particular, it included the determination of the optimal experimental parameters to obtain a grain refinement, the characterization of their effect on the solidification and the understanding of the physical mechanisms driving grain refinement. For that purpose, a Bridgman type furnace was modified in order to add an electromagnetic stirring device. Indeed, as the industrial continuous casting process is rigid and complex, the investigations were easier to carry out on the Bridgman installation, enabling us to define the influence of each experimental parameter : power of the induction, casting speed, coil position, temperature of the liquid and composition of the alloy. This experimental study was completed by the numerical simulation of the experimental conditions. The analysis of the structures, refined or not, showed that the dominant factors concerning the capacity of EMS to refine the structure, are the position of the inductor with respect to the liquidus, and the permeability of the mushy zone of the alloy. The more permeable the alloy is near the liquidus the more effective is the grain refinement. Concerning the position of the inductor, in-situ temperature measurements clearly revealed the local reheating of the liquid induced by convection. To correctly refine the low concentration alloy (C97), this local reheating must be brought on the position close to the dendrite position. During EMS-induced grain refinement, fragmentation of the dendrite arms by remelting and their survival in the melt are prevalent. Remelting can occur only if the "hot" liquid penetrates the mushy zone. Thus, the concept of permeability according to the model of Karman-Cozeny was used in simulation in order to characterize the penetration of the liquid in the mushy zone. From these results, a criterion of remelting, based on Flemings model of macrosegregation, was adapted and applied to our case. This criterion shows that remelting takes place if the velocity of the interdendritic liquid is lager than the speed of the isotherms. The velocity of the interdendritic liquid was calculated by numerical simulation for both alloys, under various experimental conditions. These results confirmed the importance to bring the inductor closer to the position of the liquidus to remelt dendrites, in particular in the case of the C97 alloy, which proves to be much more difficult to refine than the BZ4 alloy. Lastly, survival of the fragments was also studied. It depends on the casting conditions (casting speed and thermal gradient) and on the composition of the alloy. From the differences in composition of both alloys, it could be shown that the survival of dendrites fragments is improved during the solidification of the BZ4 alloy, compared with the C97 alloy.

EPFL2003