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The Al/Al2O3 composite deuterium barrier was deposited on the polished side of 316 L stainless steel by the method of radio-frequency magnetron sputtering. The influence of the introduction of Al transition layer on the deuterium resistance performance of Al2O3 ceramic coating was studied. The field emission scanning electron microscope (SEM), the grazing incident X-ray diffraction technique (GIXRD), and the auger electron spectroscopy (AES) were used to analyze the microscopic morphology, phase, and element distribution in the depth direction of the Al/Al2O3 coating, and the gas-driver permeation method was used to measure the deuterium permeation behavior of the coating sample. The results show that Al2O3 is amorphous after annealing at 873 K. Due to the oxidation of the Al transition layer, the connection between the coating and the substrate is tightly connected. Under the combined action of permeation temperature and pressure of 873 K and 80 kPa, the deuterium permeability of Al/Al2O3 coating is 6.35 × 10 − 14 mol·m-1·s-1·Pa-0.5, which shows that the Al/Al2O3 coating has excellent deuterium permeation resistance. Furthermore, deuterium permeability of the Al/Al2O3 coating was diminished by about 2 orders of magnitude compared with 316 L stainless steel, and it is reduced 2~3 times compared with the single Al2O3 coating sample. The study indicates that the introduction of the Al transition layer can significantly enhance the barrier effect of the Al/Al2O3 coating sample. [ABSTRACT FROM AUTHOR]

A deuterium permeation barrier is an essential part in the core component of nuclear reactors. It can protect the structure made of steel from being penetrated by deuterium in a fusion reactor. However, residual stress induced in the operation would dramatically influence the mechanical endurance of the coating, threatening the safety of the facilities. In this paper, finite element analysis was conducted to investigate the residual stress in nanoscale Al2O3 and Y2O3 coatings and their composites under thermal shock, from 700°C to 25°C. The max principal stress is assumed as the cause of crack initiation in the coating, because ceramics are brittle and fragile under tensile stress. Max shear stress and max Mises stress in the systems are also analyzed, and the effect of thickness in the range 100 nm to 1000 nm was investigated. The max principal stress in Al2O3 coating reaches its maximum value, 1.33 GPa, when the thickness of coating reaches 450 nm. And the max principal stress decreases at a very low rate as the thickness increases exceeding 450 nm. The max principal stress in Y2O3 coating increases rapidly as the thickness increases when the thickness of the coating is below 250 nm, and the max principal stress is at about 0.9 GPa when the thickness exceeds 500 nm. The max principal stress in the Y2O3/Al2O3 (150 nm) composite coating occurs in the Al2O3 layer and shows no difference from the single layer of 150 nm thick Al2O3 coating. The max principal stress site of all three kinds of coating is located at the edge of the coating 25 nm away from the interface. The result shows that residual thermal stress in the coating increases as the thickness increases when the thickness of the coating is below 200 nm due to the stress singularity of the interface. And as the thickness exceeds 500 nm, the increase in thickness has little impact on the residual thermal stress in the coating. Coating an Y2O3 top layer will not introduce any more residual thermal stress under the thermal shock condition. The Y2O3 coating causes much less residual stress under thermal shock compared with Al2O3 owing to its much lower Young's modulus. The max principal stress in the 300 nm thick Y2O3 coating is 0.85 GPa while that of the Al2O3 coating is 1.16 GPa. The max residual stress of the composite Y2O3/Al2O3 (150 nm) coating is determined by the Al2O3 layer. [ABSTRACT FROM AUTHOR]