Diamond Coating Reduces Nuclear Fuel Rod Corrosion at Accidental Temperatures: The Role of Surface Electrochemistry and Semiconductivity

If we want to decrease the probability of accidents in nuclear reactors, we must control the surface corrosion of the fuel rods. In this work we used a diamond coating containing <60% diamond and >40% sp² “soft” carbon phase to protect Zr alloy fuel rods (ZIRLO^®) against corrosion in steam at temperatures from 850 °C to 1000 °C. A diamond coating was grown in a pulse microwave plasma chemical vapor deposition apparatus and made a strong barrier against hydrogen uptake into ZIRLO^® (ZIRLO) under all tested conditions. The coating also reduced ZIRLO corrosion in hot steam at 850 °C (for 60 min) and at 900 °C (for 30 min). However, the protective ability of the diamond coating decreased after 20 min in 1000 °C hot steam. The main goal of this work was to explain how diamond and sp² “soft” carbon affect the ZIRLO fuel rod surface electrochemistry and semi conductivity and how these parameters influence the hot steam ZIRLO corrosion process. To achieve this goal, theoretical and experimental methods (scanning electron microscopy, Raman spectroscopy, electrochemical impedance spectroscopy, carrier gas hot extraction, oxidation kinetics, ab initio calculations) were applied. Deep understanding of ZIRLO surface processes and states enable us to reduce accidental temperature corrosion in nuclear reactors.

Corrosion-Resistant Functional Diamond Coatings for Reliable Interfacing of Liquid Metals with Solid Metals

Gallium-based liquid metals (GLMs) exist as atypical liquid-phase metals at and near room temperature while being electrically and thermally conductive, enabling copious applications in soft electronics and thermal management systems. Yet, solid metals are affected by interfacing with GLMs, resulting in liquid metal embrittlement and device failure. To avert this issue, mechanically durable and electrically tunable diffusion barriers for long-term reliable liquid metal-solid metal interfacing based on the deposition of various diamond coatings are designed and synthesized, as they feature high chemical inertness and extraordinary mechanical resistance. The diamond coatings show superlyophobicity (GLM contact angle ≥ 155°) and are nonstick toward GLMs, thereby achieving high mobility of GLM droplets (sliding angle 8-12°). The excellent barrier and anti-adhesion performance of the diamond coatings are proven in long-term experiments (3 weeks) of coated titanium alloy (Ti) samples in contact with GLMs. The electrical performance of the conductive diamond coating deposited on Ti is reliable and stable over a period of 50 h. As proof-of-concept applications a switch and a thermal management device based on liquid metals are demonstrated, signifying that coating diamond films on metals is a potent means to achieve stable integration of solid metals with GLMs.

Robust Biomimetic Hierarchical Diamond Architecture with a Self-Cleaning, Antibacterial, and Antibiofouling Surface

Biofouling is a worldwide problem from healthcare to marine exploration. Aggressive biofouling, wear, and corrosion lead to severe deterioration in function and durability. Here, micro- and nanostructured hierarchical diamond films mimicking the morphology of plant leaves were developed to simultaneously achieve superhydrophobicity, antibacterial efficacy, and marine antibiofouling, combined with mechanical and chemical robustness. These coatings were designed and successfully constructed on various commercial substrates, such as titanium alloys, silicon, and quartz glass via a chemical vapor deposition process. The unique surface structure of diamond films reduced bacteria attachment by 90-99%. In the marine environment, these biomimetic diamond films significantly reduced more than 95% adhesion of green algae. The structured diamond films retained mechanical robustness, superhydrophobicity, and antibacterial efficacy under high abrasion and corrosive conditions, exhibiting at least 20 times enhanced wear resistance than the bare commercial substrates even after long-term immersion in seawater.

Gradient-Modified HfC-SiC Mixed Bi-Interlayers Synthesized under Different TMS Flow Rate Increment for Depositing Diamond Coating onto WC-Co Substrate

To deposit well-adhered diamond coating, gradient-modified hafnium carbide-silicon carbide (HfC-SiC) mixed bi-interlayers were prepared on cemented carbides (WC-Co) by plasma surface metallurgy technique under the different tetramethylsiline (TMS) flow rate increment. The effects of the TMS flow rate increment on the composition, microstructure, adhesion, and hardness of the bi-interlayers were investigated. Then, the well-adhered bi-interlayer was chosen for the deposition of the diamond coating. It was found that the HfC-SiC mixed bi-interlayers consisted of a diffusion-modified HfC-riched inner layer and a SiC-riched outer layer. The TMS flow rate increment played a key role in tailoring the surface morphology, thickness, and interface character of the bi-interlayer. The dense nanocrystalline diamond coating was formed on the optimized bi-interlayer at the increment of 0.20 sccm/2 min. The diamond coating showed excellent adhesion, which was benefited from the cobalt (Co) diffusion inhibition, gradient composition distribution, and mechanical interlocking.

Influence of Adhesive Strength, Fatigue Strength and Contact Mechanics on the Drilling Performance of Diamond Coating

Adhesive strength of the coating significantly affects the lifetime of the coating. However, it is still inevitable for the coating, even with strong adhesive strength, to peel off from the substrate after working for a while. In this work, fatigue and wear behaviors were employed to analyze the effect on the mechanics of coating and contribute to a fundamental understanding of peeling of the coating. A small-size Co-cemented tungsten carbide drill bit was selected as the examined substrate to fabricate the diamond coating. Roughening pretreatment with a diamond slurry combined with ultrasonic vibration was performed for the substrate surface to enhance adhesive strength. Meanwhile, a diamond coating without roughening pretreatment was also fabricated for comparison. The lifetime and quality of the coating were evaluated by the drilling test. Although the diamond coating could grow on the substrates with and without roughening pretreatment, the diamond coating with roughening pretreatment possessed a higher lifetime and stronger wear resistance than that without roughening pretreatment. We found that both substrates with and without roughening pretreatment exhibited a coarse surface, whereas the roughening pretreatment could remove the original machined surface of the substrate and thus make the near surface with numerous integrated crystalline grains become the new topmost surface. This increased the contact area and surface energy of the interface, leading to the improvement of adhesive strength. Finally, fatigue strength and contact mechanics were studied to trace the changes in the stress of the diamond coating in the whole process of drilling from a theoretical point of view. We suggest that fatigue strength and contact mechanics may play vital roles on the durability and peeling of the coating.