For zirconium alloys, the practical upper temperature is governed by time-dependent corrosion, material creep and loss of ductility, well before bulk melting. In ordinary water-reactor service, cladding surfaces are commonly in the several-hundred-degree range, with normal operation around the low-to-mid range in a pressurized water reactor. A quoted service limit must specify alloy, coolant chemistry, exposure time, stress and accumulated hydrogen; there is no universal temperature at which every zirconium tube abruptly fails.
Increasing temperature accelerates zirconium-steam oxidation and creep. Oxide growth increases thermal resistance, and hydrogen uptake can leave a hydride-containing cladding with reduced resistance to cracking. A transient can also cause ballooning or rupture as hot material loses strength under internal pressure. Oxygen absorbed beneath the oxide stabilizes a brittle oxygen-rich region; a tube that survives the hot part of a transient can still have poor ductility during cooling and quenching.
For scale, the established US emergency-core-cooling criterion discussed by the United States Nuclear Regulatory Commission fuel-damage criteria limits peak cladding temperature to , about , together with an oxidation criterion. This is an accident-analysis criterion, rather than a proposed continuous service temperature.[ref]
United States Nuclear Regulatory Commission fuel-damage criteria. Issue170, description of the10CFR50.46 peak-temperature and17% oxidation criteria
These material constraints limit allowable fuel heat flux and temperature excursions and require adequate heat removal and thermal margin. A small increase in coolant temperature or oxide thermal resistance can raise the underlying metal temperature and accelerate degradation. Alloy changes, protective coatings and alternative claddings aim to improve that margin, while still satisfying the neutronic and mechanical requirements.