Formation of the Structure, Properties, and Corrosion Resistance of Zirconium Alloy Under Three-Roll Skew Rolling Conditions
Kawałek A. Arbuz A. Ozhmegov K. Volokitina I. Volokitin A. Lutchenko N. Popov F.
December 2025Multidisciplinary Digital Publishing Institute (MDPI)
Materials
2025#18Issue 24
Zirconium and its alloys are widely used in nuclear power engineering due to their favorable physical and mechanical properties and their low thermal-neutron absorption cross-section. Their high corrosion resistance in aqueous and steam environments at elevated temperatures is essential for the reliable operation of fuel assemblies and is associated with the formation of a stable, compact ZrO2 oxide layer. However, under reactor conditions, the presence of hydrogen, iodine and other fission products can reduce corrosion resistance, making detailed corrosion assessment necessary. Manufacturing technology, alongside alloy composition, also plays a decisive role in determining corrosion behavior. This study presents corrosion test results for a Zr-1%Nb alloy processed under thermomechanical conditions corresponding to rolling in a special type of three-roll skew rolling–Radial-Shear Rolling (RSR). The applied rolling technology ensured the formation of a pronounced ultrafine-grained (UFG) structure in the near-surface layers, with an average grain size below 0.6 µm. EBSD and TEM observations revealed a largely equiaxed microstructure with refined grains and increased grain boundary density. The corrosion testing was performed in high-temperature steam vessels at 400 °C and 10.3 MPa for 72, 336, 720 and 1440 h. The results demonstrate that RSR processing is an efficient alternative to conventional multi-pass normal bar rolling with vacuum heat treatments, allowing a significant reduction in processing steps and eliminating the need for expensive tooling and intermediate thermal or chemical treatments. Bars manufactured using this method meet the ASTM B351 requirements. The specific weight gain did not exceed 22 mg/dm2 after 72 h and 34.5 mg/dm2 after 336 h. After 1440 h, the samples exhibited a continuous, uniform dark-grey oxide layer with an average thickness below 5.3 µm.
corrosion behavior , corrosion testing , radial shear rolling of bars , zirconium-based alloy
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Metal Forming Department, Czestochowa University of Technology, ul. J.H. Dabrowskiego 69, Czestochowa, 42-201, Poland
Core Facilities and HPC, AEO Nazarbayev University, 53 Kabanbay Batyr Ave., Astana, 010000, Kazakhstan
Metal Forming Department, Karaganda Industrial University, 30 Republic Ave., Temirtau, 101400, Kazakhstan
Metal Forming Department
Core Facilities and HPC
Metal Forming Department
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