Cold spray deposition of 304L stainless steel to mitigate chloride-induced stress corrosion cracking in canisters for used nuclear fuel storage

A feasibility study of the cold spray deposition process of 304L stainless steel on 304 stainless steel substrates as a mitigation method for chloride-induced stress corrosion cracking (CISCC) has been investigated under various substrate conditions. The study is aimed at the application of this technology to mitigate CISCC that may potentially occur in or near the fusion welded regions of stainless steel canisters in Dry Cask Storage System (DCSS) for used nuclear fuels. Spherical gas-atomized 304L stainless steel powder, in the size range of 25 μm–44 μm, was used as feedstock powder for the cold spray process. The powder was deposited on 304 substrates with various surface conditions: as-polished, oxidized, cold-rolled, and plates with prototypical CISCC. The effects of cold spray parameters on quality of cold spray coatings were investigated. Thickness, porosity, and phases in the as-deposited materials were evaluated using scanning electron microscopy (SEM) and X-ray diffraction (XRD), and correlated with microhardness and adhesion strength measured via micro-indentation and ASTM C633 pulling test, respectively. XRD analysis of the coatings was also conducted to examine the effects of cold spray condition on residual stress state in the coating. Detailed cross-sectional examination of coating/substrate interfaces was performed with transmission electron microscopy (TEM) equipped with energy dispersive spectroscopy (EDS). Dense and continuous coatings with good adhesion strength, high hardness, and high degree of compressive stress were produced for the various substrate conditions by adjusting cold spray parameters. The results demonstrate that a cold sprayed stainless steel coating is a viable option to provide a physical barrier against CISCC in fusion weld regions of stainless steel in corrosive chloride salt-bearing environments.