Zirconium alloy products and fabrication processes

Claim 2

An article of Zircaloy alloy material having a region of microstructure adjacent a major surface of the article, said region of microstructure comprising: a substantially random distribution of precipitates, wherein said precipitates have an average size below approximately 1100 angstroms and said major surface characterized by excellent aqueous corrosion resistance as evidenced by a uniform, continuous and adherent oxide film after five days exposure to 454° C., 10.3 MPa steam.

Claim 3

The article according to claim 1 wherein said microstructure further comprises a stress relieved cold working structure.

Claim 4

The article according to claim 1 wherein said microstructure further comprises polygonal alpha grains.

Claim 5

The article according to claim 1 further comprising an anisotropic crystallographic texture.

Claim 6

The article according to claim 1 wherein said precipitates have an average size below approximately 800 angstroms.

Claim 7

The article according to claim 1 wherein said precipitates have an average size below approximately 800 angstroms, and said microstructure further comprises a stress relieved cold worked structure.

Claim 8

The article according to claim 1 wherein said precipitates have an average size below approximately 800 angstroms, and said microstructure further comprises polygonal alpha grains.

Claim 9

The article according to claim 1 wherein said precipitates have an average size below approximately 800 angstroms, and said article further comprises an anisotropic crystallographic texture.

Claim 10

An article of Zircaloy alloy material having a region of microstructure adjacent a major surface of the article, said microstructure comprising a substantially random distribution of precipitates and the average size of said precipitates being below approximately 1100 angstroms, and said major surface exhibiting a continuous and adherent oxide film, and a weight gain of about 249 mg/dm 2 or less, after five days exposure to 454° C., 10.3 MPa steam.

Claim 11

An article of Zircaloy alloy material having a region of microstructure adjacent a major surface of the article, said microstructure comprising a substantially random distribution of precipitates and the average size of said precipitates being below approximately 1100 angstroms, and said major surface exhibiting a continuous and adherent oxide film, and a weight gain of about 249 mg/dm 2 or less, after five days exposure to 454° C., 10.3 MPa steam.

Claim 12

The article according to claim 9 wherein said microstructure further comprises a stress relieved cold worked structure.

Claim 13

The article according to claim 9 wherein said microstructure further comprises polygonal alpha grains.

Claim 14

The article according to claim 9 further comprising an anisotropic crystallographic texture.

Claim 15

The article according to claim 9, wherein said precipitates have an average size below approximately 800 angstroms.

Claim 16

An article of manufacture comprising: a Zircaloy alloy produced by a thermomechanical reduction process consisting essentially of beta treating said Zircaloy alloy, and then, after the last beta treating step, alpha working said Zircaloy alloy in a number of reduction steps having alpha anneals after said steps as needed; and wherein all said alpha working and alpha anneals are performed at temperatures below about 600° C.; said alpha working including at least one hot reduction step at a temperature between about 500° and about 600° C.; said process resulting in said Zircaloy alloy having a microstructure consisting essentially of an alpha matrix, and precipitates having an average size below about 800 angstroms and which are substantially randomly distributed throughout the alpha matrix, said microstructure having excellent aqueous corrosion resistance characterized by an adherent corrosion film having a weight gain of about 249 mg/dm 2 or less, after five days exposure to a 454° C., 10.3 MPa steam test.

Claim 17

An article of manufacture comprising: a Zircaloy alloy produced by a thermomechanical reduction process consisting essentially of beta treating said Zircaloy alloy, and then, after the last beta treating step, alpha working said Zircaloy alloy in a number of reduction steps having alpha anneals after said steps as needed; and wherein all said alpha working and alpha anneals are performed at temperatures below about 600° C.; said alpha working including at least one hot reduction step at a temperature between about 500° and about 600° C.; said process resulting in said Zircaloy alloy having a microstructure consisting essentially of an alpha matrix, and precipitates having an average size below about 800 angstroms and which are substantially randomly distributed throughout the alpha matrix, said microstructure having excellent aqueous corrosion resistance characterized by an adherent corrosion film having a weight gain of about 249 mg/dm 2 or less, after five days exposure to a 454° C., 10.3 MPa steam test.

Claim 18

The article of manufacture according to claim 14 wherein said reduction steps having alpha anneals after said steps include cold reduction steps having alpha anneals at about 500° to 600° C. between said reduction steps.

Claim 19

A process for fabricating a Zircaloy alloy comprising the steps of: (1) forming precipitates having an average diameter below about 1100 angstroms; (2) then extruding said alloy at a temperature between about 500° and 600° C.; (3) then cold working said alloy in a series of cold pilgering steps, each of said cold pilgering steps proceeded by a thermal treatment step consisting essentially of only a low temperature anneal, said low temperature anneals being limited to about 500° to 600° C., a final anneal after the final cold pilger step, said final anneal being limited to about 466° to 600° C., wherein the combination of said extruding, said cold pilgering, said low temperature anneals and said final anneal act to distribute said precipitates substantially randomly through the microstructure of the alloy while maintaining the average diameter of the precipitates below about 1100 angstroms.

Claim 20

A process for fabricating a Zircaloy alloy comprising the steps of: (1) forming precipitates having an average diameter below about 1100 angstroms; (2) then extruding said alloy at a temperature between about 500° and 600° C.; (3) then cold working said alloy in a series of cold pilgering steps, each of said cold pilgering steps proceeded by a thermal treatment step consisting essentially of only a low temperature anneal, said low temperature anneals being limited to about 500° to 600° C., a final anneal after the final cold pilger step, said final anneal being limited to about 466° to 600° C., wherein the combination of said extruding, said cold pilgering, said low temperature anneals and said final anneal act to distribute said precipitates substantially randomly through the microstructure of the alloy while maintaining the average diameter of the precipitates below about 1100 angstroms.

Claim 21

A process for fabricating Zircaloy alloy shapes comprising the steps of: (1) beta treating a Zircaloy alloy billet; (2) subsequently, after the last beta treating step, hot deforming said billet at an elevated temperature and wherein all said deforming at said elevated temperature occurs below approximately 600° C.; (3) then further deforming said billet through cold working steps to bring said billet to final size; and (4) annealing said material between said cold working steps, and wherein all said annealing steps are performed at a temperature between approximately 500° and 600° C.

Claim 22

A process for fabricating Zircaloy alloy shapes comprising the steps of: (1) beta treating a Zircaloy alloy billet; (2) subsequently, after the last beta treating step, hot deforming said billet at an elevated temperature and wherein all said deforming at said elevated temperature occurs below approximately 600° C.; (3) then further deforming said billet through cold working steps to bring said billet to final size; and (4) annealing said material between said cold working steps, and wherein all said annealing steps are performed at a temperature between approximately 500° and 600° C.

Claim 23

The process according to claim 17 further comprising final annealing said material at a temperature below about 600° C. after the last cold working step.

Claim 24

The process according to claim 18 wherein said final anneal is a stress relief anneal.

Claim 25

A Zircaloy nuclear reactor component produced by the process in accordance with claim 16, wherein said Zircaloy nuclear reactor component is characterized by: a microstructure having enhanced corrosion resistance compared to a conventionally fabricated equivalent Zircaloy reactor component; precipitates distributed substantially randomly throughout said microstructure and forming an integral part of said microstructure; wherein said precipitates have an average size below approximately 800 angstroms; and said enhanced corrosion resistance of said microstructure is characterized by a continuous and adherent oxide film after five days exposure to 454° C., 10.3 MPa steam.

Claim 26

A process for fabricating Zircaloy alloy shapes comprising the steps of: (1) hot working a Zircaloy ingot to break said ingot down to an intermediate billet; (2) then beta treating said intermediate billet; and (3) after the last beta treating, heating and hot extruding said intermediate billet at elevated temperatures below 600° C. to produce a hollow cylindrical shape billet and wherein all heating of said intermediate billet after the last beta treating is limited to temperatures below 600° C.

Claim 27

A process for fabricating Zircaloy alloy shapes comprising the steps of: (1) hot working a Zircaloy ingot to break said ingot down to an intermediate billet; (2) then beta treating said intermediate billet; and (3) after the last beta treating, heating and hot extruding said intermediate billet at elevated temperatures below 600° C. to produce a hollow cylindrical shape billet and wherein all heating of said intermediate billet after the last beta treating is limited to temperatures below 600° C.

Claim 28

The process according to claim 21 further comprising the steps of: annealing said hollow cylindrical shape billet at a temperature of about 500° to 600° C.; and subsequently cold reducing the outside diameter and wall thickness of said hollow cylindrical shaped billet to produce a TREX.

Claim 29

The process according to claim 21 further comprising reducing the outside diameter and wall thickness of said hollow cylindrical shape billet through a series of cold working steps; and wherein interposed between said cold working steps are annealing steps at temperatures between about 500° to 600° C.

Claim 30

A process for fabricating Zircaloy shapes comprising: primary hot working of a Zircaloy ingot to an intermediate rectangular cross section billet; then beta treating said intermediate rectangular cross section billet; and subsequently, after the last beta treating, rolling said intermediate rectangular cross section billet to final size utilizing hot rolling, cold rolling and annealing steps; and wherein the temperature of said hot rolling, cold rolling and annealing steps which occur after said last beta treating step are limited to below about 600° C.

Claim 31

A process for fabricating Zircaloy shapes comprising: primary hot working of a Zircaloy ingot to an intermediate rectangular cross section billet; then beta treating said intermediate rectangular cross section billet; and subsequently, after the last beta treating, rolling said intermediate rectangular cross section billet to final size utilizing hot rolling, cold rolling and annealing steps; and wherein the temperature of said hot rolling, cold rolling and annealing steps which occur after said last beta treating step are limited to below about 600° C.

Claim 32

A Zircaloy nuclear reactor component produced by the process in accordance with claim 18, wherein said Zircaloy nuclear reactor component is characterized by: a microstructure having enhanced corrosion resistance compared to a conventionally fabricated equivalent Zircaloy reactor component; precipitates distributed substantially randomly throughout said microstructure and forming an integral part of said microstructure; wherein said precipitates have an average size below approximately 1100 angstroms; and said enhanced corrosion resistance of said microstructure is characterized by a continuous and adherent oxide film after five days exposure to 454° C., 10.3 MPa steam.

Claim 33

A process for fabricating Zircaloy alloy flat product comprising the steps of: (1) forming precipitates having an average diameter significantly below that observed in conventionally processed Zircaloy; (2) then hot rolling and cold rolling said alloy at a temperature below about 600° C. in a series of steps with anneals as needed; wherein all said anneals and said rolling are limited to a temperature of less than about 600° C.; wherein the combination of said rolling and said anneals act to distribute said precipitates substantially randomly through the microstructure of the alloy while maintaining the average size of said precipitates significantly below about 3000 angstroms, as observed in conventionally processed Zircaloy; (3) and then exposing said alloy to a high temperature high pressure steam test wherein a substantially uniform and adherent oxide film is formed under conditions that produce nodular corrosion in conventionally processed Zircaloy.

Claim 34

A process for fabricating Zircaloy alloy flat product comprising the steps of: (1) forming precipitates having an average diameter significantly below that observed in conventionally processed Zircaloy; (2) then hot rolling and cold rolling said alloy at a temperature below about 600° C. in a series of steps with anneals as needed; wherein all said anneals and said rolling are limited to a temperature of less than about 600° C.; wherein the combination of said rolling and said anneals act to distribute said precipitates substantially randomly through the microstructure of the alloy while maintaining the average size of said precipitates significantly below about 3000 angstroms, as observed in conventionally processed Zircaloy; (3) and then exposing said alloy to a high temperature high pressure steam test wherein a substantially uniform and adherent oxide film is formed under conditions that produce nodular corrosion in conventionally processed Zircaloy.