Designing advanced materials by environmental friendly plasma electrolytic oxidation

In the CANDU-PHWR nuclear reactors, Zr-2.5Nb coated with a black adherent oxide film of 1 to 2 μm in thickness is currently used for the manufacture of pressure tubes. The black oxide thin film has corrosion protective properties. However, it can be damaged during the regular refueling process, thus causing hydrogen/oxygen ingression. Therefore, an enhanced wear and corrosion resistance coating is needed. Plasma electrolytic oxidation (PEO) is an anodic electrochemical treatment, both cost-effective and environmentally friendly, widely used in the formation of a protective oxide film on the metal surface to enhance wear and corrosion resistance as well as prolonging component lifetime. The state of the art reveals that PEO method is suitable for improving the wear resistance of Zr-2.5Nb alloy. Few studies are performed in this field and thus, it is necessary to conduct a more detailed insight study on the processing parameters for PEO treatment. By understanding the influence of process parameters, such as electrolyte temperature and electrolyte composition, we can find the way to obtain a coating with improved mechanical and corrosion properties on zirconium alloys. (authors)