The steam oxidation of Cr-doped UN fuel pellets is analysed during sequential isothermal holds up to 720 degrees C. In situ neutron diffraction results show how Cr is accommodated in a secondary U2CrN3 phase, leading to the formation of a duplex UN/U2CrN3 microstructure. Under corrosion, the oxidation of the two phases begins at 400 degrees C for UN and 430 degrees C for U2CrN3, respectively. Because the UN phase is preferentially oxidised in the presence of U2CrN3, addition of Cr in UN based nuclear fuel is found to accelerate the corrosion rate. At 430 degrees C the oxidation of UN in the UN/U2CrN3 microstructure is similar to 5 times faster than pure UN, increasing to similar to 19 times faster at 460 degrees C. The oxidation of U2CrN3 produces UO2 via the formation of two transient intermediate phases. In situ neutron diffraction enables oxidation processes of UN and U2CrN3 components to be followed separately within the two-phase system.

The steam oxidation resistance of UN and UN-(20 vol%)ZrN fuel pellets is evaluated to enhance understanding of steam corrosion mechanisms in advanced nuclear fuel materials. In situ neutron diffraction shows the modified UN fuel pellets form a (U0.77,Zr0.23)N solid-solution and the sole crystalline oxidation product detected in bulk is (U0.77,Zr0.23)O2. U2N3 is not detected in significant quantities during the steam oxidation of UN or (U0.77,Zr0.23)N and stable lattice parameters show that hydriding does not take place. Steam oxidation rates, obtained via sequential Rietveld refinement show how (U0.77,Zr0.23)N has a higher activation energy (79 ± 1 kJmol−1 vs. 50 ± 5 kJmol−1), higher onset temperature (430 °C vs. 400 °C) and slower reaction rates for steam oxidation up to 616 °C, than pure UN. Throughout, both UN and (U0.77,Zr0.23)N exhibit linear (non-protective) oxidation kinetics, signifying that degradation of the fuel pellets is caused by the evolution of gaseous products at the interface followed by oxide scale spallation. This quantitative and mechanistic understanding of material degradation enables better defined operating regimes and points towards (U,Zr)N solid solutions as a promising strategy for the design of advanced nuclear fuel materials with enhanced steam corrosion resistance.

In this study, neutron diffraction and transmission electron microscopy (TEM) have been implemented to study the crystallographic structure of the ternary phase U2CrN3 from pellet to nano scale respectively. Recently microstructural evaluation of this ternary phase has been performed for the first time in pellet condition, overcoming the Cr evaporation issue during the conventional sintering process. In this work for the first time, the crystallographic structure of the ordered ternary U2CrN3 phase, stabilized in pellet condition, has been obtained by implementing neutron diffraction. For this study, pellets of the composite material UN with 20 vol% CrN were fabricated by powder metallurgy by mixing UN and CrN powders followed by Spark Plasma Sintering (SPS). TEM was used to investigate the nanoscale structure with a thin lamella of the order of 100–140 nm produced by focused ion beam (FIB). The neutron data revealed the phase composition of the pellet to be primarily 54(8) wt.% U2CrN3, in good agreement with the stoichiometry of starting reagents (UN and CrN powder) and metallographic analysis. Neutron data analysis confirms that all the crystallographic sites in U2CrN3 phase are fully occupied reinforcing the fully stoichiometric composition of this phase, however, the position of the N at the 4i site was found to be closer to the Cr than previously thought. TEM and selected area electron diffraction rendered nano-level information and revealed the presence of nano domains along grain boundaries of UN and U2CrN3, indicating a formation mechanism of the ternary phase, where the phase likely nucleates as nano domains in UN grains from migration of Cr.

Thermophysical properties and oxidation behaviour of the composite pellet UN–20 vol%ZrN were investigated experimentally and compared with the behaviour of the pure UN pellet. A compound of a single phase, a solid solution of the average composition U0.8Zr0.2N, was obtained by Spark Plasma Sintering (SPS) of the powders UN and ZrN. Crystallographic and microstructural characterisation of the composite was performed using Scanning Electron Microscopy (SEM), standardised Energy Dispersive Spectroscopy (EDS) and Electron Backscatter Diffraction (EBSD). Nano hardness and Young's modulus were also measured by the nanoindentation method. High-Temperature X-ray diffraction (XRD) was applied to obtain the lattice expansion as a function of temperature (room temperature to 673 K). Thermogravimetric Analysis (TGA) was applied to evaluate oxidation behaviour in air. Results demonstrate that the fabrication method results in a matrix of solid solution with homogeneous composition averaged to U0.8Zr0.2N. The mechanical properties of such solution are uniform, with variation only due to the crystallographic orientation of the grains of the solution phase, similar to pure UN. The obtained value for the average linear thermal expansion coefficient is α¯ = 7.94 × 10-6/K, which compares well to UN (α¯ = 7.95 × 10-6/K) for the same temperature range. The degradation behaviour of the composite pellet UN-20 vol%ZrN in air shows a lower oxidation onset temperature, compared to pure UN, with the final product of oxidation being mainly U3O8. Smaller crystallites in the product of corrosion of the composite pellet indicate that the mechanism of degradation of the solid solution phase U0.8Zr0.2N is accompanied by the formation of two distinct oxides and their interaction.

In the present study, physical properties of the ternary phase U2CrN3 are evaluated experimentally and by modeling methods. High density pellets containing the ternary phase were prepared by spark plasma sintering (SPS). The microstructural and crystallographic analyses of the composite pellets were performed using scanning electron microscopy (SEM), standardised energy dispersive spectroscopy (EDS) and electron backscatter diffraction (EBSD). Evaluation of the mechanical properties was performed by nanoindentation test. The impact of temperature on lattice properties was evaluated using high temperature X-ray diffraction (XRD) coupled with modeling. Progressive change in the lattice parameters was obtained from room temperature (RT) to 673 K, and the result was used to calculate average linear thermal expansion coefficients, as well as an input for the density functional theory (DFT) modeling to reassess the degradation of the mechanical properties. The ab-initio calculation provides an initial assessment of electronic configuration of this ternary phase in a direct comparison with one of UN phase. For this goal, modeling was also employed to evaluate point defect formation energies and electronic charge distribution in the ternary phase. Results indicate that the U2CrN3 phase has similar mechanical properties to UN (Young's, bulk, shear moduli, hardness). No preferential crystallographic orientation was observed in the composite pellet. However, charge electron density distribution highlights the significant directionality of chemical bonds, which is in agreement with the anisotropy and non-linear behaviour of the obtained thermal expansion (α¯(aa) = 9.12 × 10−6/K, α¯(ab) = 5.81 × 10−6/K and α¯(ac) = 6.08 × 10−6/K). As a consequence, uranium was found to be more strongly bound in the ternary structure which may delay diffusion and vacancy formation, promising an acceptable performance as nuclear fuel.