A comparative study of the wear performance of hard coatings for nuclear applications

Hard chromium plate (HCP) has been the wear resistant coating of choice in the nuclear industry for decades, but new protective coatings are required as a result of the hazardous nature of Cr(VI) compounds used in electroplating. This study compares the wear performance of candidate replacements materials, Cr2O3 and Cr3C2-NiCr. These two coatings are also compared with HCP and a WC-(W,Cr)(2)C-Ni coating assessed in an earlier publication. The Cr2O3 and Cr3C2-NiCr coatings were supplied having been applied to Inconel 625 substrates using high velocity oxy fuel (HVOF) and thermal detonation gun spray techniques, respectively. A ball-on-flat sliding wear configuration was used with three environments: dry, deionised water, and borated water to partially simulate nuclear reactor water chemistry. Wear rates were measured using both volume and mass standard metrics. The wear surface samples were characterised using scanning electron microscopy (SEM) and X-ray photoelectron spectroscopy (XPS) in order to establish the operative wear mechanisms. All three candidate coating materials exhibited similar wear performance to HCP in the three test environments. There was, however, enough of a difference between performance in deionised and borated water, to merit the use of borated water in future testing. The data gathered using SEM and XPS provided insight into the wear mechanisms. These include both particle pull-out and tribolayer formation. The XPS data revealed that Cr3C2 is preferentially removed from the Cr3C2-NiCr coating during wear testing in a borated water environment.

Automated summary

This study compared the wear performance of candidate replacement materials, Cr2O3 and Cr3C2-NiCr, with traditional HCP coating, revealing similar performance in different testing environments but with significant differences in deionised water and borated water, suggesting the merit of using borated water in future testing. Insights into wear mechanisms were provided through SEM and XPS data, including particle pull-out and tribolayer formation, with preferential removal of Cr3C2 observed in a borated water environment during wear testing.