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URLhttps://onlinelibrary.wiley.com/doi/10.1002/smll.202503963
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Meta TitleSurface Modification of Zirconium Alloy with Nanocrystalline Diamond: Enhancing Quenching Performance for Accident Tolerant Fuel - Xu - Small - Wiley Online Library
Meta DescriptionTo enhance Zr fuel cladding's accident tolerance, a nanocrystalline diamond (NCD) coating is applied via hot-filament chemical vapor deposition (HFCVD). Tests show the NCD coating significantly impro..., Abstract Nuclear energy remains a critical component of the global energy, yet its safety, particularly under extreme conditions, has been a major concern since the Fukushima Daiichi accident. Zirc...
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Nuclear energy remains a critical component of the global energy, yet its safety, particularly under extreme conditions, has been a major concern since the Fukushima Daiichi accident. Zirconium (Zr) alloys are widely used as fuel cladding in light water reactors due to their excellent nuclear properties, but their reaction with high-temperature steam during loss-of-coolant accidents(LOCA) poses a significant risk of hydrogen explosions. To enhance the accident tolerance of Zr alloy cladding, this article proposes a surface modification approach using nanocrystalline diamond (NCD) coatings to improve boiling heat transfer performance. High-temperature quenching experiments are conducted, supported by high-speed camera, scanning electron microscopy (SEM), and Raman spectroscopy. The results demonstrate that the NCD coating (1 µm thick) significantly enhances heat transfer performance: it reduces re-wetting time (12.33 s vs. 15.67 s, a 21.3% improvement), increases the maximum cooling rate (111.48 ° C s −1 vs. 94.73 ° C s −1 , a 17.7% enhancement), and elevates the Leidenfrost temperature to 572.24 (15.06% higher than bare Zr alloy). Thermodynamic parameter calculations indicate that the NCD enhances heat transfer efficiency by improving the solid–liquid contact temperature parameter ( k ρ c ). Furthermore, Raman spectroscopy confirms the coating's stability. This article provides critical experimental and theoretical insights for developing accident tolerant fuel (ATF) claddings, offering significant implications for improving the safety of nuclear reactors.
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- Skip to Article Content - Skip to Article Information [![Wiley Online Library](https://onlinelibrary.wiley.com/pb-assets/hub-assets/pericles/logo-header-1690978619437.png)](https://onlinelibrary.wiley.com/) [![Wiley Online Library](https://onlinelibrary.wiley.com/pb-assets/hub-assets/pericles/mobilehublogo-1690978876347.png)](https://onlinelibrary.wiley.com/) Search within Login / Register - [Individual login](https://onlinelibrary.wiley.com/action/showLogin?acdl-redirect=true&uri=%2Fdoi%2F10.1002%2Fsmll.202503963) - [Institutional login](https://onlinelibrary.wiley.com/action/ssostart?redirectUri=%2Fdoi%2F10.1002%2Fsmll.202503963) - [REGISTER](https://onlinelibrary.wiley.com/action/registration?redirectUri=%2Fdoi%2F10.1002%2Fsmll.202503963&acdl-redirect=true) [![](https://pubads.g.doubleclick.net/gampad/ad?iu=$googlePublisherCategory&sz=728x90&tile=1&c=$random)](https://onlinelibrary.wiley.com/action/clickThrough?id=1013&url=https%3A%2F%2Fpubads.g.doubleclick.net%2Fgampad%2Fjump%3Fiu%3D%24googlePublisherCategory%26amp%3Bsz%3D728x90%26amp%3Btile%3D1%26amp%3Bc%3D%24random&loc=%2Fdoi%2F10.1002%2Fsmll.202503963&pubId=89243174&placeholderId=1015&productId=101018) [Small](https://onlinelibrary.wiley.com/journal/16136829 "Small homepage") [Early View](https://onlinelibrary.wiley.com/toc/16136829/0/0) e03963[![Small](https://onlinelibrary.wiley.com/pb-assets/journal-banners/16136829-1590659348003.jpg)](https://onlinelibrary.wiley.com/journal/16136829 "Small homepage") Research Article # Surface Modification of Zirconium Alloy with Nanocrystalline Diamond: Enhancing Quenching Performance for Accident Tolerant Fuel [Wei Xu](https://onlinelibrary.wiley.com/authored-by/Xu/Wei), Corresponding Author Wei Xu - [\[email protected\]](https://onlinelibrary.wiley.com/cdn-cgi/l/email-protection#205745497f585560534a54550e4544550e434e "Link to email address") - [orcid.org/0000-0003-2102-8902](https://orcid.org/0000-0003-2102-8902) College of Smart Energy, Shanghai Jiao Tong University, Shanghai, 200240 China E-mail: [\[email protected\]](https://onlinelibrary.wiley.com/cdn-cgi/l/email-protection#e1968488be9994a1928b9594cf848594cf828f "Link to email address"); [\[email protected\]](https://onlinelibrary.wiley.com/cdn-cgi/l/email-protection#bbc3d2dad4d1d2d5dcd7d2cefbc8d1cfce95dedfce95d8d5 "Link to email address") [Search for more papers by this author](https://onlinelibrary.wiley.com/authored-by/Xu/Wei) [Ningkang Zhao](https://onlinelibrary.wiley.com/authored-by/Zhao/Ningkang), Ningkang Zhao - [orcid.org/0009-0001-6229-4636](https://orcid.org/0009-0001-6229-4636) College of Smart Energy, Shanghai Jiao Tong University, Shanghai, 200240 China [Search for more papers by this author](https://onlinelibrary.wiley.com/authored-by/Zhao/Ningkang) [Meiqi Song](https://onlinelibrary.wiley.com/authored-by/Song/Meiqi), Meiqi Song College of Smart Energy, Shanghai Jiao Tong University, Shanghai, 200240 China [Search for more papers by this author](https://onlinelibrary.wiley.com/authored-by/Song/Meiqi) [Xiaojing Liu](https://onlinelibrary.wiley.com/authored-by/Liu/Xiaojing), Corresponding Author Xiaojing Liu - [\[email protected\]](https://onlinelibrary.wiley.com/cdn-cgi/l/email-protection#730b1a121c191a1d141f1a0633001907065d1617065d101d "Link to email address") - [orcid.org/0000-0003-4912-9019](https://orcid.org/0000-0003-4912-9019) School of Nuclear Science and Engineering, Shanghai Jiao Tong University, Shanghai, 200240 China E-mail: [\[email protected\]](https://onlinelibrary.wiley.com/cdn-cgi/l/email-protection#cabdafa395b2bf8ab9a0bebfe4afaebfe4a9a4 "Link to email address"); [\[email protected\]](https://onlinelibrary.wiley.com/cdn-cgi/l/email-protection#79011018161310171e15100c390a130d0c571c1d0c571a17 "Link to email address") [Search for more papers by this author](https://onlinelibrary.wiley.com/authored-by/Liu/Xiaojing) [Wei Xu](https://onlinelibrary.wiley.com/authored-by/Xu/Wei), Corresponding Author Wei Xu - [\[email protected\]](https://onlinelibrary.wiley.com/cdn-cgi/l/email-protection#582f3d3107202d182b322c2d763d3c2d763b36 "Link to email address") - [orcid.org/0000-0003-2102-8902](https://orcid.org/0000-0003-2102-8902) College of Smart Energy, Shanghai Jiao Tong University, Shanghai, 200240 China E-mail: [\[email protected\]](https://onlinelibrary.wiley.com/cdn-cgi/l/email-protection#106775794f686550637a64653e7574653e737e "Link to email address"); [\[email protected\]](https://onlinelibrary.wiley.com/cdn-cgi/l/email-protection#7d05141c121714131a1114083d0e17090853181908531e13 "Link to email address") [Search for more papers by this author](https://onlinelibrary.wiley.com/authored-by/Xu/Wei) [Ningkang Zhao](https://onlinelibrary.wiley.com/authored-by/Zhao/Ningkang), Ningkang Zhao - [orcid.org/0009-0001-6229-4636](https://orcid.org/0009-0001-6229-4636) College of Smart Energy, Shanghai Jiao Tong University, Shanghai, 200240 China [Search for more papers by this author](https://onlinelibrary.wiley.com/authored-by/Zhao/Ningkang) [Meiqi Song](https://onlinelibrary.wiley.com/authored-by/Song/Meiqi), Meiqi Song College of Smart Energy, Shanghai Jiao Tong University, Shanghai, 200240 China [Search for more papers by this author](https://onlinelibrary.wiley.com/authored-by/Song/Meiqi) [Xiaojing Liu](https://onlinelibrary.wiley.com/authored-by/Liu/Xiaojing), Corresponding Author Xiaojing Liu - [\[email protected\]](https://onlinelibrary.wiley.com/cdn-cgi/l/email-protection#512938303e3b383f363d382411223b25247f3435247f323f "Link to email address") - [orcid.org/0000-0003-4912-9019](https://orcid.org/0000-0003-4912-9019) School of Nuclear Science and Engineering, Shanghai Jiao Tong University, Shanghai, 200240 China E-mail: [\[email protected\]](https://onlinelibrary.wiley.com/cdn-cgi/l/email-protection#9cebf9f5c3e4e9dceff6e8e9b2f9f8e9b2fff2 "Link to email address"); [\[email protected\]](https://onlinelibrary.wiley.com/cdn-cgi/l/email-protection#7d05141c121714131a1114083d0e17090853181908531e13 "Link to email address") [Search for more papers by this author](https://onlinelibrary.wiley.com/authored-by/Liu/Xiaojing) First published: 12 September 2025 <https://doi.org/10.1002/smll.202503963> [Read the full text](https://onlinelibrary.wiley.com/doi/full/10.1002/smll.202503963) [About]() [![](https://onlinelibrary.wiley.com/specs/products/acropolis/pericles/releasedAssets/images/pdf-icon-169a2eb30e52100e76dfa5f4b66998e6.png)PDF](https://onlinelibrary.wiley.com/doi/epdf/10.1002/smll.202503963 "ePDF") [Tools](https://onlinelibrary.wiley.com/doi/10.1002/smll.202503963) - [Request permission](https://onlinelibrary.wiley.com/action/rightsLink?doi=10.1002%2Fsmll.202503963&mode=) - [Export citation](https://onlinelibrary.wiley.com/action/showCitFormats?doi=10.1002%2Fsmll.202503963) - [Add to favorites](https://onlinelibrary.wiley.com/personalize/addFavoritePublication?doi=10.1002%2Fsmll.202503963) - [Track citation](https://onlinelibrary.wiley.com/action/addCitationAlert?doi=10.1002%2Fsmll.202503963) [Share](https://onlinelibrary.wiley.com/doi/10.1002/smll.202503963)[Share](https://onlinelibrary.wiley.com/doi/10.1002/smll.202503963) Give access [Share full text access](https://onlinelibrary.wiley.com/doi/10.1002/smll.202503963) Share full-text access Share a link Share on - [Email]("Email") - [Facebook]("Facebook") - [x]("x") - [LinkedIn]("LinkedIn") - [Reddit]("Reddit") - [Wechat]("Wechat") - [Bluesky]("Bluesky") ### Abstract Nuclear energy remains a critical component of the global energy, yet its safety, particularly under extreme conditions, has been a major concern since the Fukushima Daiichi accident. Zirconium (Zr) alloys are widely used as fuel cladding in light water reactors due to their excellent nuclear properties, but their reaction with high-temperature steam during loss-of-coolant accidents(LOCA) poses a significant risk of hydrogen explosions. To enhance the accident tolerance of Zr alloy cladding, this article proposes a surface modification approach using nanocrystalline diamond (NCD) coatings to improve boiling heat transfer performance. High-temperature quenching experiments are conducted, supported by high-speed camera, scanning electron microscopy (SEM), and Raman spectroscopy. The results demonstrate that the NCD coating (1 µm thick) significantly enhances heat transfer performance: it reduces re-wetting time (12.33 s vs. 15.67 s, a 21.3% improvement), increases the maximum cooling rate (111.48 °*C s*−1 vs. 94.73 °*C s*−1, a 17.7% enhancement), and elevates the Leidenfrost temperature to 572.24 (15.06% higher than bare Zr alloy). Thermodynamic parameter calculations indicate that the NCD enhances heat transfer efficiency by improving the solid–liquid contact temperature parameter (*k*ρ*c*). Furthermore, Raman spectroscopy confirms the coating's stability. This article provides critical experimental and theoretical insights for developing accident tolerant fuel (ATF) claddings, offering significant implications for improving the safety of nuclear reactors. ## Conflict of Interest The authors declare no conflict of interest. ## [Open Research](https://onlinelibrary.wiley.com/doi/10.1002/smll.202503963) # # Data Availability Statement The data that support the findings of this study are available from the corresponding author upon reasonable request. ## [Supporting Information]() | Filename | Description | |---|---| | [smll70295-sup-0001-SuppMat.pdf](https://onlinelibrary.wiley.com/action/downloadSupplement?doi=10.1002%2Fsmll.202503963&file=smll70295-sup-0001-SuppMat.pdf)572\.7 KB | Supporting Information | Please note: The publisher is not responsible for the content or functionality of any supporting information supplied by the authors. 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