Corrosion of Chromia and Alumina Forming Ferritic Stainless Steels under Dual Atmosphere Exposure Conditions

Surface morphology and chemistry of oxide scales formed on select chromia and alumina forming ferritic steels have been studied after exposure to a dual atmosphere of hydrogen and air. Localized Fe-rich oxide nodules with surface whiskers/platelets form at the onset of corrosion. The initiation and growth of localized nodules and breakdown of the passivation are attributed to the presence of hydrogen, inclusion of iron oxide in the passivating scale, and subsequent growth of iron-rich oxide due to the establishment of redox (H2-H2O) atmosphere and modification of oxide defect chemistry.

Effect of Shot Peening on the Evolution of Scale on T91 Steel Exposed to Steam

Shot peening can be an effective solution for the prevention or retardation of scale formation, and subsequent exfoliation, upon exposure of the inner tube to steam in coal-fired power plants. In this study, specimens of T91 tubes were shot peened and then exposed to 1-bar steam for 100–1000 h at 650 °C, and were then analyzed using Vickers hardness test and microscopic techniques OM, SEM, TEM, etc. The analysis indicates that the oxide scales are typically Fe2O3 on the topmost layer, Fe3O4 below, and a FeCr2O4 spinel on the bottom in both shot peening treated and untreated specimens. However, the oxide scale thicknesses of shot peened specimens are thinner, indicating that shot peened specimens have better oxidation resistance. In addition, numerous defects, such as voids and micro-cracks, were found in the untreated specimens, which are believed to cause exfoliation of the uppermost Fe2O3 layers of the specimens exposed to steam for 800 and 1000 h. By contrast, the shot peened specimens maintained a dense contact oxide scale with fewer defects.

The Effect of Al on the Formation of a CrTaO4 Layer in Refractory High Entropy Alloys Ta-Mo-Cr-Ti-xAl

In this study, the effect of Al on the high temperature oxidation of Al-containing refractory high entropy alloys (RHEAs) Ta-Mo-Cr-Ti-xAl (x = 5; 10; 15; 20 at%) was examined. Oxidation experiments were performed in air for 24 h at 1200 °C. The oxidation kinetics of the alloy with 5 at% Al is notably affected by the formation of gaseous MoO3 and CrO3, while continuous mass gain was detected for alloys with the higher Al concentrations. The alloys with 15 and 20 at% Al form relatively thin oxide scales and a zone of internal corrosion due to the formation of dense CrTaO4 scales at the interface oxide/substrate. The alloys with 5 and 10 at% Al exhibit, on the contrary, thick and porous oxide scales because of fast growing Ta2O5. The positive influence of Al on the formation of Cr2O3 followed by the growth of CrTaO4 to yield a compact scale is explained by getter and nucleation effects.

High-Temperature Oxidation Behavior of Fe–10Cr Steel under Different Atmospheres

Using a thermogravimetric analyzer (TGA), Fe–10Cr steel was oxidized in dry air and in a mixed atmosphere of air and water vapor at a relative humidity of 50% and a temperature of 800–1200 °C for 1 h. The oxidation weight gain curves under the two atmospheres were drawn, the oxidation activation energy was calculated, and the phase and cross-sectional morphology of the iron oxide scales were analyzed and observed by X-ray diffractometry (XRD) and optical microscopy (OM). The results showed that when the oxidation temperature was 800 °C, the spheroidization of Fe–10Cr steel occurred, and the oxidation kinetics conformed to the linear law. At 900–1200 °C, the oxidation kinetics followed a linear law in the preliminary stage and a parabolic law in the middle and late stages. In an air atmosphere, when the oxidation temperature reached 1200 °C, Cr2O3 in the inner oxide layer was partially ruptured. In an atmosphere with a water vapor content of 50%, Cr2O3 at the interface reacted with H2O to generate volatile CrO2(OH)2, resulting in a large consumption of Cr at the interface. At the same time, a large number of voids and microcracks appeared in the iron oxide layer, which accelerated the entry of water molecules into the substrate, as well as the oxidation of Fe–10Cr steel, and caused the iron oxide scales to fall off. Due to the volatilization of Cr2O3 and the conversion from internal oxidation to external oxidation, the internal oxidation zone (IOZ) of Fe–10Cr steel under water vapor atmosphere decreased or even disappeared.

Effect of Total Pressure and Furnace Tube Material on the Oxidation of T22 in Humidified Air

Oxidation of the Fe-base alloy T22 in humid air at 500 °C was investigated. The samples were exposed for up to 1000 h at 1 bar and 20 bar. The influence of three furnace tube materials, alumina, ET45 and quartz glass, on the oxide scale morphology was investigated. Samples and their cross sections were examined using optical microscopy, scanning electron microscopy, electron probe micro analysis and Raman spectroscopy. Multilayered oxide scales consisting of hematite, magnetite and Fe–Cr spinel were found on all samples. However, the composition and morphology of the oxide scales depend on the furnace tube material and on the system pressure. The system pressure is assumed to change the reaction equilibria and adsorption rates. The tube material changed the initial gas composition by formation of volatile Cr species. This volatilization rate increased at higher system pressures.

Behavior of Silicon Carbide Materials under Dry to Hydrothermal Conditions

Silicon carbide materials are excellent candidates for high-performance applications due to their outstanding thermomechanical properties and their strong corrosion resistance. SiC materials can be processed in various forms, from nanomaterials to continuous fibers. Common applications of SiC materials include the aerospace and nuclear fields, where the material is used in severely oxidative environments. Therefore, it is important to understand the kinetics of SiC oxidation and the parameters influencing them. The first part of this review focuses on the oxidation of SiC in dry air according to the Deal and Grove model showing that the oxidation behavior of SiC depends on the temperature and the time of oxidation. The oxidation rate can also be accelerated with the presence of H2O in the system due to its diffusion through the oxide scales. Therefore, wet oxidation is studied in the second part. The third part details the effect of hydrothermal media on the SiC materials that has been explained by different models, namely Yoshimura (1986), Hirayama (1989) and Allongue (1992). The last part of this review focuses on the hydrothermal corrosion of SiC materials from an application point of view and determine whether it is beneficial (manufacturing of materials) or detrimental (use of SiC in latest nuclear reactors).

Strain-aging-assisted localized corrosion of a mill-scaled X-65 pipeline steel

This investigation was designed to study whether strain aging could assist localized corrosion of pipeline steels under realistic conditions, which is an unsolved problem in the evaluation of strain-aging-induced stress corrosion cracking of pipeline steels in the field. It was found that the corrosion severity was significantly aggravated after strain aging because of the increase in yield strength and the transformation of oxide scales on the steel surface. These variations caused by strain aging lead to lesser exfoliation and longer life of the oxide scales under cyclic loading in air and during subsequent corrosion exposure, which enhances the galvanic corrosion between oxide scales and the steel substrate. The composition of oxide scales, mechanical properties of steels, and magnitude of the stress cycles, which could all impact localized corrosion, were studied. The findings of this investigation suggest that the severe localized corrosion leading to crack initiation is a vital factor for the higher SCC susceptibility of pipeline steels associated with strain aging, in addition to the enhanced hydrogen embrittlement as usually believed.