Cr-coated Zr alloys are widely considered the most promising accident-tolerant fuel (ATF) cladding materials for engineering applications in the near term. In this work, Cr coatings were prepared on the surfaces of 1400 mm long N36 cladding tubes using an industrial multiple arc source system. Orthogonal analyses were conducted to demonstrate the significance level of various process parameters influencing the characteristics of coatings (surface roughness, defects, crystal orientation, grain structure, etc.). The results show that the arc current mainly affects the coating deposition rate and the droplet particles on the surface or inside the coatings; however, the crystal preferred orientation and grain structure are more significantly influenced by the gas pressure and negative bias voltage, respectively. Then, the underlying mechanisms are carefully discussed. At last, a set of systemic methods to control the quality and microstructures of Cr coatings are summarized.

Zirconium monoxide (ZrO) plays a key role in the water-side corrosion resistance of Zr alloys as cladding materials in nuclear reactors. This study investigates the behavior of intrinsic defects in ZrO through first-principles calculations, and the influence of main alloying elements (Cr, Fe, Nb and Sn) is also evaluated. We focus on the formation and migration properties of vacancies and interstitials. The results show that the formation energy of oxygen vacancy is 5.31 eV. The formation energy of interstitial O_i-tet in ZrO is −4.04 eV, indicating that O_i-tet can be formed spontaneously. Another interstitial oxygen O_i-mid with a formation energy of 0.03 eV can also be found in large quantities in ZrO. As for the migration properties, oxygen vacancy in ZrO without doping tends to diffuse along Path 2, and the diffusion barrier is 2.96 eV. Cr and Fe reduce the migration barriers of oxygen vacancies, while Nb and Sn increase them. In contrast, alloying elements generally hinder the formation of oxygen interstitials and increase their migration barriers, particularly in the case of Cr and Fe. The migration barrier of interstitial oxygen diffusion along Path a in pure ZrO is 2.91 eV. However, the migration barriers of interstitial oxygen in ZrO with Cr or Fe doping could increase to more than 4 eV. These findings provide critical insights into the role of alloying elements in modifying defect dynamics, offering a theoretical basis for improving the corrosion resistance and performance of zirconium alloys in practical applications.