Experimental Study on Fretting Wear Characteristic of Zr-4 Alloy
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摘要:
核燃料棒包壳微动磨损特性对反应堆系统安全性至关重要。为研究Zr-4合金包壳微动磨损特性，本文通过搭建微动磨损实验装置，采用线接触方式开展Zr-4合金微动磨损实验研究，针对不同位移幅值研究Zr-4合金微动磨损的微观形貌和元素变化及其磨损机制。结果表明：位移幅值增大导致磨损现象加剧，最大磨损深度和磨损体积增加，尤其在加速磨损区Zr-4合金微动损伤加速恶化，最大磨损深度和磨损体积的增长速率分别达到峰值0.34 μm/μm、0.52×10−2 mm3/μm。整个微动磨损过程中，磨损区域均伴随着Zr、Fe、Cr等金属氧化物的产生，局部磨损区域存在磨屑的转移与黏着。低磨损区的整个损伤区域被平滑的三体层覆盖；加速磨损区的整个损伤区域存在凹痕形成和三体层动态变换现象；稳定磨损区的损伤中心区域三体层发生片状脱落，并伴有微观裂纹萌生。本文研究结果为Zr-4合金包壳在压水堆服役中的微动磨损行为提供了数据参考。
Abstract:Nuclear energy, as a safe, clean, and efficient low-carbon energy source, has become an important option for achieving sustainable energy and power development. However, during the operation of pressurized water reactors, flow-induced vibrations can trigger fretting wear behavior in Zr-4 alloy cladding, causing damage to the contact surface and leading to the failure of nuclear fuel assemblies, potentially resulting in the leakage of nuclear fission products. To investigate the fretting wear characteristics of Zr-4 alloy cladding, a fretting wear experimental device was independently designed and constructed for studying the wear behavior of Zr-4 alloy under line contact with different displacement amplitudes. The fretting wear of Zr-4 alloy was divided into three zones based on displacement amplitude: low wear zone, accelerated wear zone, and stable wear zone. A white light interferometer was used to obtain the 3D morphology and wear quantities (wear volume and maximum wear depth) of the damaged areas, while scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) were used to analyze the microscopic morphology and elemental distribution of the damaged areas. The microstructural characteristics of the fretting wear zones in Zr-4 alloy were studied, focusing on the changes in micro-morphology, elemental composition, and wear mechanisms. The results indicate that an increase in displacement amplitude intensifies the wear phenomena, with maximum wear depth and wear volume increasing. Particularly, in the accelerated wear zone, fretting wear to Zr-4 alloy deteriorates more rapidly. The growth rates of both maximum wear depth and wear volume reach their peak and then decrease. Throughout the fretting wear process, metal oxides such as Zr, Fe, and Cr are generated and removed from the wear zones. The Fe content in the damaged area gradually decreases and stabilizes, while the oxygen content initially increases, reaching a peak in the accelerated wear zone before beginning to decrease. In localized wear zones, the transfer and adhesion of wear debris are observed. The low wear zone is covered by a smooth tribological layer. The wear mechanisms in this zone involve adhesive wear, mild abrasive wear, and oxidative wear. In the accelerated wear zone, indentation formation and dynamic changes in the tribological layer occur, with a weakening of adhesive wear and an enhancement of abrasive wear. In the stable wear zone, the tribological layer in the center damage area peels off in flakes, accompanied by the initiation of micro-cracks. Abrasive wear becomes more severe, along with significant oxidative wear. The results show that displacement amplitude significantly affects the fretting wear mechanism of Zr-4 alloy. This study reveals the fretting wear behavior and mechanisms of Zr-4 alloy cladding, providing valuable data and theoretical support for the safe operation and life assessment of Zr-4 alloy cladding in pressurized water reactors.
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Keywords:
- cladding ,
- Zr-4 alloy ,
- fretting wear ,
- wear mechanism
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图 2 Zr-4合金与304不锈钢接触示意图
Figure 2. Schematic diagram of contact between Zr-4 alloy and 304 stainless steel
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图 3 不同位移幅值下Zr-4合金损伤区域的部分三维形貌
Figure 3. Partial 3D morphology of Zr-4 alloy damage area at different displacement amplitudes
a——D=5 μm；b——D=20 μm；c——D=60 μm
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图 4 不同位移幅值下Zr-4合金最大磨损深度、磨损体积的变化趋势
Figure 4. Trend in maximum wear depth and wear volume of Zr-4 alloy at different displacement amplitudes
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图 5 不同位移幅值下Zr-4合金损伤中心区域EDS面扫描分析结果
a——低磨损区（D=10 μm）；b——加速磨损区（D=20 μm）；c——稳定磨损区（D=60 μm）；d——未磨损区
Figure 5. EDS mapping analysis result of damage center area of Zr-4 alloy at different displacement amplitudes
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图 6 不同磨损区域下Zr-4合金损伤中心区域EDS面扫描分析结果
a——损伤中心区域元素含量；b——损伤中心区域O元素含量
Figure 6. EDS mapping analysis result of damage center area of Zr-4 alloy in different wear zones
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图 7 不同磨损区域下Zr-4合金损伤中心区域EDS点扫描分析结果
a——低磨损区（D=10 μm）；b——加速磨损区（D=20 μm）；c——稳定磨损区（D=60 μm）
Figure 7. EDS point analysis result of damage center area of Zr-4 alloy in different wear zones
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图 8 不同磨损区域下Zr-4合金损伤中心区域微观形貌
a——低磨损区（D=10 μm）；b——加速磨损区（D=20 μm）；c——稳定磨损区（D=40 μm）；d——稳定磨损区（D=60 μm）
Figure 8. Micromorphology of damage center area of Zr-4 alloy in different wear zones
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图 9 不同磨损区域的磨损机制示意图
a——低磨损区（D=10 μm）；b——加速磨损区（D=20 μm）；c——稳定磨损区（D=40 μm）；d——稳定磨损区（D=60 μm）
Figure 9. Schematic diagram of wear mechanism in different wear zones
表 1 实验材料主要参数
Table 1 Main parameter of experimental material
材料 长度L/mm 外径ϕ/mm 表面粗糙度Ra/μm Zr-4合金 160.00 9.50 ≤0.3 304不锈钢 10.00 9.50 ≤0.1 
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表 2 微动磨损实验参数
Table 2 Fretting wear experimental parameter
参数 参数值 温度，℃ 20 压力，MPa 0.101 3 频率，Hz 10 法向载荷，N 10 循环次数 106 位移幅值，μm 5～60
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