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Evaluation of Thermal Spray Alumina Coatings on Nickel Electrode Connector for Reprocessing Applications

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Abstract

Electro-oxidative dissolution of the spent mixed oxide nuclear fuels with high plutonium content from prototype fast breeder reactor need to be carried out in boiling 11.5 M HNO3. Nickel electrode connectors employed in the electrolyser of the dissolver should possess good corrosion resistance as well as good electrical conductivity. Alumina coating deposited on Ni by plasma spraying was evaluated by electrochemical polarization and impedance experiments in 11.5 M HNO3 at room temperature. In order to improve corrosion resistance, alumina coating relatively denser than plasma spray coating was deposited over Ni by detonation gun (D-gun) spray coating. This alumina coating exhibited a high insulation resistance and the weight loss of alumina coated Ni disc was only 3% compared to 29% for bare Ni disc sample when exposed to the vapour of 11.5 M boiling HNO3 for 12 h. However, coating delamination observed at the alumina/bond coat interface was attributed to the penetration of HNO3 vapour through the pores in the coating. Since alumina coating deposited by D-gun technique over Ni was also found to offer only short-term protection against corrosion due to HNO3 vapour, monolithic dense alumina sleeve fabricated through powder metallurgy route was recommended instead of coating, for better corrosion protection in HNO3 vapour compared to thermal spray coating.

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Authors and Affiliations

  1. Corrosion Science and Technology Division, Indira Gandhi Centre for Atomic Research, Kalpakkam, 603102, India

    A. Ravi Shankar, Ch. Jagadeeswara Rao, E. Vetrivendan, C. Mallika & U. Kamachi Mudali

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  1. A. Ravi Shankar
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  2. Ch. Jagadeeswara Rao
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  3. E. Vetrivendan
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  4. C. Mallika
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  5. U. Kamachi Mudali
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Correspondence to U. Kamachi Mudali.

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Ravi Shankar, A., Jagadeeswara Rao, C., Vetrivendan, E. et al. Evaluation of Thermal Spray Alumina Coatings on Nickel Electrode Connector for Reprocessing Applications. Trans Indian Inst Met 71, 297–307 (2018). https://doi.org/10.1007/s12666-017-1160-4

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  • DOI: https://doi.org/10.1007/s12666-017-1160-4

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