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The current work is part of the EPSRC MUZIC project, which established the collaboration among several universities to carry out a multidiscipline study on the breakaway oxidation of zirconium alloys. The overall goal of the project is to further understand the mechanisms of the oxidation and breakaway process of zirconium alloys. This thesis describes the nano/micro-structural study and nano-analysis of the corroded zirconium alloys using up-to-date TEM and 3D focused ion beam (FIB) slicing and reconstruction techniques. The work mainly focused on the characterization of ZIRLO. The oxide morphology in general comprises an inner columnar layer and an outer equiaxed layer, except for a post-second transition oxide grown on a Zr-Nb-Ti test alloy with a very poor corrosion resistance, which exhibits generally only equiaxed grains throughout the whole oxide scale. Detailed investigation reveals oxides in a slower oxidation stage exhibit better developed columnar grain structure. All the oxides, independent of different corrosion stages and alloy types, contain predominantly monoclinic oxide and a small amount of tetragonal oxide. Defects at different length scales were examined. In stead of a sudden burst of crack nucleation at the kinetic transition, a gradual introduction of cracks parallel to the metal/oxide interface throughout the pre-transition stage is found, suggesting no direction correlation between the formation of cracks and the transition. Besides cracks, the oxide also contains different forms of nano-porosity: isolated pores of 1-3 nm or interconnected pores at grain boundaries. The density of interconnected porosity, especially those along the oxide growth direction, increases towards the oxide surface, evolving over time. It is suggested that the kinetic transition is related to the development of an interconnected porosity down to the metal/oxide interface, providing easy pathways for the transportation of oxidation species. The metal-oxide interface has a wavy morphology both in the micrometer and nanometer scale. The roughness develops to a maximum just before the first kinetic transition. An intermediate suboxide layer with complex 3D morphology between the bulk oxide and the metal substrate is found. Quantitative EELS analysis shows the composition of this layer to be 40-50 at. % oxygen. The suboxide appears to develop in thickness with increasing oxidation time for the pre-transition oxides, while is very thin or absent in the post-, and post-second transition oxides. In the suboxide region, multiple phases including α-Zr, ω-Zr, tetragonal oxide and a phase with an unidentified structure were found, suggesting different structures can coexist in the suboxide layer. Second-phase particles (SSPs) of β-Nb and hexagonal Zr(Fe,Nb)₂ types were found in ZIRLO samples and FCC Zr(Fe,Cr)₂ was the predominant type in Zircaloy-4. The SPPs showed delayed oxidation compared to surrounding Zr. In ZIRLO, those containing high Fe contents were found to be oxidized and transform into an amorphous state much earlier than β-Nb. Hydrides of different types (γ, σ and ε) were observed in the metal and metal/oxide region for both Zircaloy-4 and ZIRLO samples. A higher density of hydrides was seen in post-transition oxides of ZIRLO than in pre-transition oxides.

Thermal barrier coatings (TBCs) of ZrO2-7wt% Y2O3 were deposited by electron beam physical vapor deposition (EB-PVD) onto stationary flat plates and cylindrical surfaces in a multiple ingot coater. Crystallographic texture, microstructure, and deposition rate were investigated in this thesis. The crystallographic texture of EB-PVD TBCs deposited on stationary flat surfaces has been experimentally determined by comparing pole figure analysis data with actual column growth angle data. It was found that the TBC coating deposited directly above an ingot exhibits <220> single crystal type crystallographic texture. Coatings deposited between and off the centerline of the ingots the exhibited a <311>-type single crystal texture. For coatings deposited in the far corners of the coating chamber either a <111> fiber texture or a <311> single crystal type texture existed. The crystallographic texture of EB-PVD TBCs deposited on cylindrical surfaces was characterized using x-ray diffraction (XRD) at different angular positions on the cylinder substrate. XRD results revealed that crystallographic texture changes with angular position. Changes in crystallographic texture are attributed to the growth direction of the columns and substrate temperature. Growth direction is controlled by the direction of the incoming vapor flux (i.e. vapor incidence angle), in which competition occurs between crystallites growing at different rates. The fastest growing orientation takes over and dominates the texture. Substrate temperature variations throughout the coating chamber resulted in different growth rates and morphology. Morphology differences existed between cylindrical and flat plate surfaces. Flat cross sectional surfaces of the coatings exhibited a dense columnar structure in which the columns grew towards the closest vapor source. Surface features were found to be larger for coatings deposited directly above an ingot than coatings deposited away from the ingots. Morphological differences result from substrate temperature changes within the coating chamber, which influences growth kinetics of the coating. Cylindrical surfaces revealed a columnar structure in which columns grew towards the closest vapor. Porosity of the coating was found to increase when the angular position changed from the bottom of the cylinder. Change in angular position also caused the column diameter to decreases. Morphology changes are attributed to self-shadow effects caused by the surface curvature of the cylinder and vapor incidence angle changes. Overall, the microstructure and crystallographic texture of EB-PVD coatings was found to depend on the position in the coating chamber which was found to influence substrate temperature, growth directions, and shadowing effects. The coating thickness profiles for EB-PVD TBCs deposited on stationary cylinders have been experimentally measured and theoretically modeled using Knudsen's cosine law of emissions. A comparison of the experimental results with the model reveals that the model must to be modified to account for the sticking coefficient as well as a ricochet factor. These results are also discussed in terms of the effects of substrate temperature on the sticking coefficient, the ricochet factor, and coating density.

Thesis (M.S.)--Massachusetts Institute of Technology, Dept. of Materials Science and Engineering, 1980. / MICROFICHE COPY AVAILABLE IN ARCHIVES AND SCIENCE. / Includes bibliographical references. / by Pierre Leon Jacques Chemelle. / M.S.

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Mechanical milling (alloying) is one of the non-equilibrium techniques used to prepare alloys with exceptional properties. This technique was employed in this research to develop a new class of Al- and Mg-based nanocomposite alloys using SPEX high energy milling. These nanocomposites are characterized by the dispersion of nanocrystals in an amorphous matrix. Zirconium was added to the Al-Mg alloys for the purpose of promoting glass formability. As-milled samples were annealed at 400°C for 1 hour to investigate the thermal stability of the nanostructure. The phase evolution of the resulting alloys was studied using XRD and TEM/EDS, which showed a strong dependence of the resulting metastable phases on the starting alloys compositions. / The nanocomposite structure was developed at Zr concentrations of 20 and 35 at.% regardless of the Al/Mg ratio and with some traces of oxidation. However, the amount of amorphous phase was varied in each case depending on the Al concentration into the alloy, since in low Al-containing alloys the amount of amorphous phase was less pronounced. It was found that higher Zr concentrations will lead to greater refinement of the nanostructure. These nanocomposites showed improved mechanical properties, in terms of higher hardness values, in addition to improved thermal stability. The improvement in thermal stability was attributed to the presence of Al3Zr which proved to contribute significantly to retarding grain growth via grain boundary pinning. / Additionally, the employment of mechanical alloying was beneficial in producing Al3Zr in the cubic L12 ordered structure which improves the ductility of the alloy. Moreover, the homogeneity ranges of gamma-Al 12Mg17 and Al3Zr were extended significantly due to the nature of the non-equilibrium processing. In this research, the alloy with the maximum hardness was Al40Mg25Zr35, which has an average hardness value close to 780 HV and average crystallite size of about 10 nm. A common observation in the alloys that showed a higher hardness values combined with improved thermal stability, is that they contain higher Al and Zr concentrations. / Le broyage mécanique est une technique hors équilibre qui permet la fabricationde nouveaux alliages avec des propriétés exceptionnelles. Lors de cette recherche, unbroyeur SPEX 8000 a été utilisé pour développer une nouvelle classe denanocomposites à base d'aluminium et de magnésium. Ces nanocomposites tirent leurspécificité de leur dispersion de nanocrystaux dans une matrice amorphe. Duzirconium a été ajouté aux alliages d'aluminium et de magnésium pour promouvoirl'amorphisation. Les échantillons de poudres broyées ont été recuits à 400°C pour 1heure pour évaluer la stabilité thermique des différentes phases. Leur évolution a étécaractérisée par diffraction par rayon-X et par MEBIEDS. TI fut démontré que lesphases métastables obtenues dépendent fortement de la composition des alliages dedépart.

Made available in DSpace on 2014-10-09T12:52:04Z (GMT). No. of bitstreams: 0 / Made available in DSpace on 2014-10-09T13:58:08Z (GMT). No. of bitstreams: 0 / Dissertação (Mestrado) / IPEN/D / Instituto de Pesquisas Energeticas e Nucleares - IPEN/CNEN-SP

Cette thèse est axée sur la caractérisation microstructurale des précipités dans les oxydes des alliages binaires de zirconium (1 wt.% Fe, Cr , Ni ou 0.6 wt.% Nb). La température d'oxydation est fixée au 415°C. Les échantillons sont oxydés dans l'air et dans l'autoclave sous des pressions différentes et dans un microscope électronique à balayages environnemental sous vapeur d'eau. Les résultats des recherches peuvent être résumés ci-dessous : -Deux types d'oxydation (retardée et non retardée) ont été observés pour les précipités. -Le facteur de Pilling-Bedworth des précipités est plus élevé par rapport à celui de zirconium. -Les précipités contenant du fer entrainent une formation des cristaux de l'oxyde de fer pur à la surface du matériau, quand les précipités sont à la surface ou à la proximité. Ces observations mènent à la conclusion que le comportement d'oxydation des précipités peut être corrélé à leurs compositions et à la tendance d'oxydation de leurs éléments constituants. / This thesis is focused on the microstructural characterisation of precipitates in the oxide of binary zirconium alloys (1 wt.% Fe, Cr or Ni or 0.6 wt.% Nb) under different oxidation conditions at 415°C. The samples were oxidised in autoclave in air and steam and in an environmental scanning electron microscope in water vapour. The microstructural evolution of the precipitates during oxidation was characterised using electron microscopy. The findings from the analysis are the following: -Two types of oxidation behaviour are observed for precipitates. -Pilling-Bedworth ratio of precipitates is higher than that of the zirconium matrix. -Formation of pure iron oxide crystals on the surface for iron bearing precipitates close to or at the surface. From these observations it is concluded that the precipitate oxidation behaviour can be correlated to precipitate composition and oxidation tendency of the elements in the precipitates. Iron exhibits clearly different behaviour.