An Orthogonal Experimental Study on the Preparation of Cr Coatings on Long-Size Zr Alloy Tubes by Arc Ion Plating

Cr-coated Zr alloys are widely considered the most promising accident-tolerant fuel (ATF) cladding materials for engineering applications in the near term. In this work, Cr coatings were prepared on the surfaces of 1400 mm long N36 cladding tubes using an industrial multiple arc source system. Orthogonal analyses were conducted to demonstrate the significance level of various process parameters influencing the characteristics of coatings (surface roughness, defects, crystal orientation, grain structure, etc.). The results show that the arc current mainly affects the coating deposition rate and the droplet particles on the surface or inside the coatings; however, the crystal preferred orientation and grain structure are more significantly influenced by the gas pressure and negative bias voltage, respectively. Then, the underlying mechanisms are carefully discussed. At last, a set of systemic methods to control the quality and microstructures of Cr coatings are summarized.