Uranium corrosion

W. D. Wilkinson, Uranium Metallurgy, Vol. 1, Trocess Metallurgy, Vol. 11, Uranium Corrosion and Alloys, Wdey-lnterscience, New York, 1962. 

Both zirconium hydride and zirconium metal powders compact to fairly high densities at conventional pressures. During sintering the zirconium hydride decomposes and at the temperature of decomposition, zirconium particles start to bond. Sintered zirconium is ductile and can be worked without difficulty. Pure zirconium is seldom used in reactor engineering, but the powder is used in conjunction with uranium powder to form uranium—zirconium aUoys by soHd-state diffusion. These aUoys are important in reactor design because they change less under irradiation and are more resistant to corrosion. 

The rate (kinetics) and the completeness (fraction dissolved) of oxide fuel dissolution is an inverse function of fuel bum-up (16—18). This phenomenon becomes a significant concern in the dissolution of high bum-up MO fuels (19). The insoluble soHds are removed from the dissolver solution by either filtration or centrifugation prior to solvent extraction. Both financial considerations and the need for safeguards make accounting for the fissile content of the insoluble soHds an important challenge for the commercial reprocessor. If hydrofluoric acid is required to assist in the dissolution, the excess fluoride ion must be complexed with aluminum nitrate to minimize corrosion to the stainless steel used throughout the facility. Also, uranium fluoride complexes are inextractable and formation of them needs to be prevented. 

The fifth component is the stmcture, a material selected for weak absorption for neutrons, and having adequate strength and resistance to corrosion. In thermal reactors, uranium oxide pellets are held and supported by metal tubes, called the cladding. The cladding is composed of zirconium, in the form of an alloy called Zircaloy. Some early reactors used aluminum fast reactors use stainless steel. Additional hardware is required to hold the bundles of fuel rods within a fuel assembly and to support the assembhes that are inserted and removed from the reactor core. Stainless steel is commonly used for such hardware. If the reactor is operated at high temperature and pressure, a thick-walled steel reactor vessel is needed. 

The corrosion behavior of plutonium metal has been summarized (60,61). a-Plutonium oxidizes very slowly in dry air, typically <10 mm/yr. The rate is accelerated by water vapor. Thus, a bright metal surface tarnishes rapidly in normal environments and a powdery surface soon forms. Eventually green PUO2 [12059-95-9] covers the surface. Plutonium is similar to uranium with respect to corrosion characteristics. The stabilization of 5-Pu confers substantial corrosion resistance to Pu in the same way that stabilization of y-U yields a more corrosion-resistant metal. The reaction of Pu metal with Hquid water produces both oxides and oxide-hydrides (62). The reaction with water vapor above 100°C also produces oxides and hydride (63). 

Properties. Uranium metal is a dense, bright silvery, ductile, and malleable metal. Uranium is highly electropositive, resembling magnesium, and tarnishes rapidly on exposure to air. Even a poHshed surface becomes coated with a dark-colored oxide layer in a short time upon exposure to air. At elevated temperatures, uranium metal reacts with most common metals and refractories. Finely divided uranium reacts, even at room temperature, with all components of the atmosphere except the noble gases. The silvery luster of freshly cleaned uranium metal is rapidly converted first to a golden yellow, and then to a black oxide—nitride film within three to four days. Powdered uranium is usually pyrophoric, an important safety consideration in the machining of uranium parts. The corrosion characteristics of uranium have been discussed in detail (28). 

Uranium hexafluoride [7783-81-5], UF, is an extremely corrosive, colorless, crystalline soHd, which sublimes with ease at room temperature and atmospheric pressure. The complex can be obtained by multiple routes, ie, fluorination of UF [10049-14-6] with F2, oxidation of UF with O2, or fluorination of UO [1344-58-7] by F2. The hexafluoride is monomeric in nature having an octahedral geometry. UF is soluble in H2O, CCl and other chlorinated hydrocarbons, is insoluble in CS2, and decomposes in alcohols and ethers. The importance of UF in isotopic enrichment and the subsequent apphcations of uranium metal cannot be overstated. The U.S. government has approximately 500,000 t of UF stockpiled for enrichment or quick conversion into nuclear weapons had the need arisen (57). With the change in pohtical tides and the downsizing of the nation s nuclear arsenal, debates over releasing the stockpiles for use in the production of fuel for civiUan nuclear reactors continue. 

Zirconium is used as a containment material for the uranium oxide fuel pellets in nuclear power reactors (see Nuclearreactors). Zirconium is particularly usehil for this appHcation because of its ready availabiUty, good ductiUty, resistance to radiation damage, low thermal-neutron absorption cross section 18 x 10 ° ra (0.18 bams), and excellent corrosion resistance in pressurized hot water up to 350°C. Zirconium is used as an alloy strengthening agent in aluminum and magnesium, and as the burning component in flash bulbs. It is employed as a corrosion-resistant metal in the chemical process industry, and as pressure-vessel material of constmction in the ASME Boiler and Pressure Vessel Codes. 

Polychlorotrifluoroethylene was the first fluorinated polymer to be produced on an experimental scale and polymers were used in Germany and in the United States early in World War II. PCTFE was used, in particular, in connection with the atomic bomb project in the handling of corrosive materials such as uranium hexafluoride. 

Carbide-based cermets have particles of carbides of tungsten, chromium, and titanium. Tungsten carbide in a cobalt matrix is used in machine parts requiring very high hardness such as wire-drawing dies, valves, etc. Chromium carbide in a cobalt matrix has high corrosion and abrasion resistance it also has a coefficient of thermal expansion close to that of steel, so is well-suited for use in valves. Titanium carbide in either a nickel or a cobalt matrix is often used in high-temperature applications such as turbine parts. Cermets are also used as nuclear reactor fuel elements and control rods. Fuel elements can be uranium oxide particles in stainless steel ceramic, whereas boron carbide in stainless steel is used for control rods. 

For many years the corrosion of uranium has been of major interest in atomic energy programmes. The environments of importance are mainly those which could come into contact with the metal at high temperatures during the malfunction of reactors, viz. water, carbon dioxide, carbon monoxide, air and steam. In all instances the corrosion is favoured by large free energy and heat terms for the formation of uranium oxides. The major use of the metal in reactors cooled by carbon dioxide has resulted in considerable emphasis on the behaviour in this gas and to a lesser extent in carbon monoxide and air. 

The solid corrosion products in carbon dioxide and carbon monoxide are uranium dioxide, uranium carbides and carbon. The major reaction with carbon dioxide results in the formation of carbon monoxide ... 

The mechanisms of corrosion by steam are similar to those for water up to 450°C, but at higher temperatures are more closely related to the behaviour in carbon dioxide. Studies at 100°C have demonstrated that uranium hydride is produced during direct reaction of the water vapour with the metal and not by a secondary reaction with the hydrogen product. Also at 100°C it has been shown that the hydride is more resistant than the metal. Inhibition with oxygen reduces the evolution of hydrogen and does not involve reaction of the oxygen with the uranium . Above 450°C the hydride is not... 

The behaviour of uranium has been well characterised for a variety of environments of importance in the nuclear industry. The corrosion is governed by the constitution and physical character of the solid reaction products which in turn are determined mainly by the oxygen potential of the environment, the temperature and the presence of water. The mechanisms of attack are known in broad outline. A major area in need of more detailed study is the influence of irradiation both prior to and during oxidation. 

Extensive work into the corrosion and oxidation of uranium and its alloys has been undertaken over the past decade but much of this is in the form of Ministry and industrial reports which are not necessarily readily available. The present review concentrates on the work published in the normal scientific and technical press. 

Galvanic corrosion reports have emerged from two sources. In the first , the chemical compatibility of uranium carbides and Cr-Fe-Ni alloys was discussed. Evaluation was by thermodynamic modelling and experimental... 

Bourns, W. T., Corrosion Testing of Uranium Silicide Fuel Specimens, AECL-2 718 (1968)... 

There are a number of industrial gas separation systems that use the selective permeability of plastics to separate the constituents. In design problems relating to such applications, the designer must consider the environmental conditions to determine whether the materials having the desired properties will withstand the temperatures and physical and chemical stresses of the application. Frequently the application will call for elevated temperatures and pressures. In the case of uranium separation, the extreme corrosivity of the fluorine compounds precluded the use of any material but PTFE. The PTFE... 

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