Ceramic plasma-sprayed coating of melting crucibles for casting metal fuel slugs

Thermal cycling and melt reaction studies of ceramic coatings plasma-sprayed on Nb substrates were carried out to evaluate the performance of barrier coatings for metallic fuel casting applications. Thermal cycling tests of the ceramic plasma-sprayed coatings to 1450°C showed that HfN, TiC, ZrC, and Y2O3 coating had good cycling characteristics with few interconnected cracks even after 20 cycles. Interaction studies by 1550°C melt dipping tests of the plasma-sprayed coatings also indicated that HfN and Y2O3 do not form significant reaction layer between U–20wt.% Zr melt and the coating layer. Plasma-sprayed Y2O3 coating exhibited the most promising characteristics among HfN, TiC, ZrC, and Y2O3 coating.