Benchmarking SiC f /SiC, FeCrAl, and Cr-coated Zr alloy claddings: evaluating thermomechanical properties and high-temperature oxidation resistance of next-generation nuclear claddings

Although nuclear energy is a clean and sustainable source, inherent safety concerns have long been recognized and were critically highlighted by the Chernobyl and Fukushima accidents. A significant amount of research is focused on improving accident-tolerant fuel (ATF) technologies to enhance the safety features of reactors. Choosing the right material for the fuel-rod cladding is the most crucial part of the nuclear fuel system and is necessary to develop ATF ideas. Concerning their thermomechanical integrity, high-temperature oxidation resistance, irradiation tolerance, and manufacturability for light-water reactors (LWRs), this review offers a thorough benchmarking of three top ATF cladding candidates – silicon carbide fiber-reinforced silicon carbide composites (SiCf/SiC), iron-chromium-aluminum alloys (FeCrAl), and chromium-coated zirconium alloy (Cr-coated Zr-alloy). Moreover, it addresses the performance metrics gap by elucidating the qualification pathways, including lead test rod campaigns, hermetic joining techniques for SiCf/SiC, weld optimization for FeCrAl, and comprehensive uniformity controls for Cr-coated Zr-alloy. This review further defines an executable R&D plan for the mid-2030s deployment of ATF claddings in current LWR fleets by directly comparing critical criteria and identifying feasible certification and licensing policies.