Trace elements can reduce the fracture resistance of Zr-2.5Nb pressure tubes. The effects of hydrogen as hydrides and oxygen as an alloy-strengthening agent are well known, but the contributions of carbon, phosphorus, chlorine, and segregated oxygen have only recently been recognized. Carbides and phosphides are brittle particles, while chlorine segregates to form planes of weakness that produce fissures on the fracture face of test specimens. A high density of fissures is associated with low toughness. With long hold times in the (α + β) region, oxygen partitions into the α-grains; such grains are hard and, if they survive fabrication, may reduce the toughness of the finished tube. Through a cooperative program involving AECL and the manufacturers, a series of manufacturing innovations and controls has been introduced that minimizes these harmful effects.

Hydrogen is present in the zirconium sponge as water, can be absorbed at each stage of tube fabrication, and needs to be carefully controlled, particularly during ingot breakdown and subsequent forging. Hydrogen concentrations in finished tubes have been reduced by a factor of three through the optimization of manufacturing processes and the implementation of new technology. Multiple vacuum arc melting, use of selected raw materials, and intermediate ingot surface conditioning have resulted in much improved fracture toughness through the reduction of chlorine and phosphorus concentrations. Optimum distribution of oxygen may be achieved through changes to the extrusion process cycle. An understanding of the Zr-2.5Nb-C phase diagram, particularly the solubility of carbon at low concentrations, has resulted in the specification of a lower carbon concentration.