Chemical milling of zircaloy tubing to produce integral OD spiral finned tubes. AWBA development program

A detailed process description is provided for producing integral spiral fins on the outside surface of Zircaloy nuclear fuel cladding tubes by masking with pressure sensitive tape strips and then chemical milling (pickling) the tube wall between the tape strips to leave the fins in relief. Fins up to 0.020 inch high by 0.05 to 0.12 inch wide were consistently produced on tubes having wall thickness of 0.008 inch or greater after fin pickling. Wall thickness uniformity was excellent. Information is provided on tube surface preparation to maximize tape mask adhesion time during pickling, acid chemistry control to prevent local tube wall thinning near the fin, and pickling techniques to promote uniform material removal. Simple fixture designs are described for quickly and conveniently applying the tape strips to the tube wall in an accurate spiral.