To improve the high-temperature steam oxidation resistance of Zr alloys under loss-of-coolant accident (LOCA) conditions, a ZrO2/CrAlSi composite coating was fabricated on Zr-2 alloy via plasma electrolytic oxidation (PEO) followed by filtered cathodic vacuum arc deposition (FCVAD). The coating exhibited superior protection in 1100 °C steam for up to 180 min, with oxidation kinetics transitioning from parabolic to accelerated behavior after 144 min. Microstructural analysis revealed that outward diffusion of Cr and Al formed a protective Al2O3/Cr2O3 scale, significantly reducing oxygen permeability compared to conventional Cr coatings (∼1 μm vs. 4.9–8 μm oxide thickness at 60 min). Inward Si migration generated a Zr2Si diffusion barrier within the PEO interlayer, effectively suppressing Cr penetration into the substrate. However, prolonged exposure (180 min) led to Zr2Si oxidation and the precipitation of brittle CrZr2(Al,O) phases. The PEO interlayer played a critical role in mitigating elemental interdiffusion (Zr, Cr, Al, Si, O) and reducing oxygen permeability, thereby enhancing coating durability. This study demonstrates that the synergistic effects of Al2O3/Cr2O3 scale formation, Zr2Si diffusion barrier, and PEO-mediated diffusion control significantly enhance the oxidation resistance of Zr alloys, making the PEO/CrAlSi coating a promising candidate for accident-tolerant fuel cladding applications.
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