Ultra-high resistance to electrochemical and high-temperature steam corrosion of MAO/Cr bilayer coatings fabricated on Zr alloys

doi:10.1016/j.jmst.2025.04.047

Abstract

Abstract: In this work, MAO/Cr bilayer coatings were deposited on Zr alloys by combining micro-arc oxidation (MAO) and high-impulse-power magnetron sputtering (HiPIMS) techniques. The coating exhibited outstanding resistance to electrochemical and high-temperature steam corrosion. As the surface defects of the MAO interlayer increased the nucleation sites of Cr grains, it refined the grain size of the Cr top layer, which could promote the growth of passive film in lithium borate aqueous solution and enhance its corrosion resistance. Moreover, under the simulated loss-of-coolant accident (LOCA) scenario, the MAO/Cr bilayer coating exhibited a weight gain roughly 34.9 % lower than the Cr coating after oxidation for 90 min. This was primarily due to the MAO interlayer inhibiting interdiffusion at the coating-substrate interface and reducing the rapid diffusion paths for oxygen in the residual Cr coating during oxidation.

Key words: MAO/Cr bilayer coating, Zr alloy, HiPIMS, Electrochemical corrosion, High-temperature steam oxidation

Zheng Wang, Yingpeng Zhang, Zhichao Han, Zhenyu Wang, Wei Yang, Ming Li, Aiying Wang, Peiling Ke. Ultra-high resistance to electrochemical and high-temperature steam corrosion of MAO/Cr bilayer coatings fabricated on Zr alloys[J]. J. Mater. Sci. Technol., 2026, 244: 273-284.

References

[1] M. Daunys, R. Dundulis, A. Grybenas, P. Krasauskas, Nucl. Eng. Des. 238(2008) 2536-2545.
[2] A.S. Agazhanov, D.A. Samoshkin, S.V. Stankus, Thermophys. Aeromech. 28(2021) 577-581.
[3] V.E. Peletsky, High Temp.- High Press. 31(1999) 627-632.
[4] K.A. Terrani, J. Nucl. Mater. 501(2018) 13-30.
[5] J. Yang, M. Steinbrück, C. Tang, M. Große, J. Liu, J. Zhang, D. Yun, S. Wang, J. Alloys Compd. 895(2022) 162450.
[6] W. Zhang, Y. Qian, R. Sun, X. Lin, M. Yao, Y. Qiu, J. Yang, G. Cheng, J. Dong, Corros. Sci. 191(2021) 109722.
[7] Y. Wang, B. Chen, X.-Z. Wang, M.Chen, S. Li, G. Bai, J. Li, W. Gong, Corros. Sci. 217(2023) 111099.
[8] H.-G. Kim, I.-H. Kim, Y.-I. Jung, D.-J. Park, J.-Y. Park, Y.-H. Koo, J. Nucl. Mater. 465(2015) 531-539.
[9] J. Ko, J.W. Kim, H.W. Min, Y. Kim, Y.S. Yoon, J. Nucl. Mater. 561(2022) 153562.
[10] X.P. Wang, H.H. Guan, Y.Z. Liao, M.H. Zhu, C. Xu, X.Y. Jin, B. Liao, W.B. Xue, Y.W. Zhang, G.H. Bai, R.S. Wang, Corros. Sci. 187(2021) 109494.
[11] P. Lai, H. Zhang, L. Zhang, Q. Zeng, J. Lu, X. Guo, Wear 424 (2019) 53-61.
[12] L. Zhang, P. Lai, Q. Liu, Q. Zeng, J. Lu, X. Guo, J. Nucl. Mater. 499(2018) 401-409.
[13] Y. Xiang, S. Zhao, C. Liu, H. Yang, W. Zhang, H. Wang, R. Zhang, H. He, S. Liu, Corros. Sci. 212(2023) 110923.
[14] X. Han, C. Chen, Y. Tan, W. Feng, S. Peng, H. Zhang, Corros. Sci. 174(2020) 108826.
[15] J.-C. Brachet, E.Rouesne, J. Ribis, T. Guilbert, S. Urvoy, G. Nony, C. Toffolon-Mas-clet, M. Le Saux, N. Chaabane, H. Palancher, A. David, J. Bischoff, J. Augereau, E. Pouillier, Corros. Sci. 167(2020) 108537.
[16] N. Attarzadeh, C.V. Ramana, Coatings 11 (2021) 620.
[17] X. Qi, B. Jiang, R. Song, Corros. Sci. 199(2022) 110164.
[18] C. Xu, M. Zhu, H. Guan, C. Gao, X. Jin, J. Du, W. Xue, Corros. Sci. 209(2022) 110711.
[19] K.J. Wei, X.P. Wang, M.H. Zhu, H.H. Guan, C. Xu, W.B. Xue, J.L. Zhang, Corros. Sci. 181(2021) 109216.
[20] X.P. Wang, K.J. Wei, H.H. Guan, C. Xu, W.B. Xue, Y.W. Zhang, R.S. Wang, Surf. Coat. Technol. 407(2021) 126768.
[21] R. Lan, L. Dong, C. Wang, T. Liang, J. Tian, Rare Metal Mater. Eng. 42(2013) 6 81-6 84.
[22] R. Polini, M. Barletta, Diamond Relat. Mater. 17(2008) 325-335.
[23] C. Tang, M. Steinbrueck, M. Stueber, M. Grosse, X. Yu, S. Ulrich, H.J. Seifert, Corros. Sci. 135(2018) 87-98.
[24] Z. Wang, Z. Wang, A. Wang, W. Yang, P. Ke, Acta Metall. Sin. 60(2024) 691-698.
[25] Z. Wang, W. Li, Z. Wang, M. Li, A. Wang, P. Ke, Ceram. Int. 49(2023) 22736-22744.
[26] X.P. Wang, Y.Z. Liao, C. Xu, H.H. Guan, M.H. Zhu, C.L. Gao, X.Y. Jin, P. Pang, J.C. Du, B. Liao, W.B. Xue, J. Alloys Compd. 883(2021) 160798.
[27] W.T. Li, Z.Y. Wang, J.T. Shuai, B.B. Xu, A.Y. Wang, P.L. Ke, Ceram. Int. 45(2019) 13912-13922.
[28] X. Zuo, P. Ke, R. Chen, X. Li, M. Oden, A. Wang, Phys. Plasmas 24 (2017) 083507.
[29] A. Anders, Surf. Coat. Technol. 257(2014) 308-325.
[30] S. Song, B. Chen, H. Li, R. Shi, C. Liu, B. Yang, G.F. de la Fuente, J.Mater. Sci. 58(2023) 7136-7148.
[31] C. Gautier, J. Machet, Thin Solid Films 289 (1996) 34-38.
[32] Y. Meng, S. Zeng, Z. Teng, X. Han, H. Zhang, Thin Solid Films 730 (2021) 138699.
[33] J.M. Zhang, K.W. Xu, M.R. Zhang, Acta Phys. Sin. 52(2003) 1207-1212.
[34] Y. Zhang, Q. Wang, G. Chen, C.S. Ramachandran, Surf. Coat. Technol. 403(2020) 126380.
[35] Y. Zhang, H. Li, L. Cui, W. Yang, G. Ma, R. Chen, P. Guo, P. Ke, A. Wang, Corros. Sci. 227(2024) 111738.
[36] Y. Zhang, X. Zhou, R. Chen, W. Yang, P. Guo, K. Nishimura, X. Li, A. Wang, Cor-ros. Sci. 240(2024) 112504.
[37] Y. Li, H. Cao, H. Li, J. Yang, F. Qi, L. Lu, N. Zhao, Y. Zhou, X. Ouyang, Surf. Coat. Technol. 448(2022) 128942.
[38] X. Nie, Y. Tang, F. Zhao, S. Luo, W. He, C. Wei, J. Song, Z. Pang, AIP Adv. 12(2022) 015211.
[39] H.H. Kim, J.H. Kim, J.Y. Moon, H.S. Lee, J.J. Kim, Y.S. Chai, J. Mater. Sci.Technol. 26(2010) 827-832.
[40] H. Yeom, B. Maier, G. Johnson, T. Dabney, M. Lenling, K. Sridharan, J. Nucl. Mater. 526(2019) 151737.
[41] Z. Wang, Y. Zhang, S. Zhou, Z. Wang, Y. Yao, A. Wang, M. Li, P. Ke, Corros. Com-mun. 14(2024) 49-57.
[42] Z. Han, Z. Wang, Z. Wang, S. Tan, A. Wang, Z. Piao, P. Ke, Surf. Coat. Technol. 488(2024) 130941.
[43] X. Wang, J.A. van Bokhoven, D.Palagin, Phys. Chem. Chem. Phys. 19(2017) 30513-30519.