Interdiffusion and reaction between Zr and Al alloys from 425° to 625 °C

Zirconium has recently garnered attention for use as a diffusion barrier between U-Mo nuclear fuels and Al cladding alloys. Interdiffusion and reactions between Zr and Al, Al-2 wt.% Si, Al-5 wt.% Si or AA6061 were investigated using solid-to-solid diffusion couples annealed in the temperature range of 425° to 625 °C. In the binary Al and Zr system, the Al3Zr and Al2Zr phases were identified, and the activation energy for the growth of the Al3Zr phase was determined to be 347 kJ/mol. Negligible diffusional interactions were observed for diffusion couples between Zr vs. Al-2 wt.% Si, Al-5 wt.% Si and AA6061 annealed at or below 475 °C. In diffusion couples with the binary Al-Si alloys at 560 °C, a significant variation in the development of the phase constituents was observed including the thick τ1 (Al5SiZr2) with Si content up to 12 at.%, and thin layers of (Si,Al)2Zr, (Al,Si)3Zr, Al3SiZr2 and Al2Zr phases. The use of AA6061 as a terminal alloy resulted in the development of both τ1 (Al5SiZr2) and (Al,Si)3Zr phases with a very thin layer of (Al,Si)2Zr. At 560 °C, with increasing Si content in the Al-Si alloy, an increase in the overall rate of diffusional interaction was observed; however, the diffusional interaction of Zr in contact with multicomponent AA6061 with 0.4-0.8 wt.% Si was most rapid.