Microstructure and corrosion behavior of Zr–1.0Cr–0.4Fe–xMo alloys

Possibility of using Mo as an alloying element in Zr-based alloys was attractive in terms of microstructure refinement and mechanical properties strengthening. In this research, Zr–1.0Cr–0.4Fe–xMo(0, 0.2, 0.4, and 0.6) alloys with different Mo contents were prepared by vacuum arcmelting method, the microstructure and the corrosion resistance of these alloys were investigated. Addition of Mo has a refinement effect on the microstructure; with the increase of Mo content, the a-laths in the as-cast samples and the grain size in the annealed samples decrease. Zr–1.0Cr–0.4Fe–xMo alloys have large numbers of fine second-phase particles(SPPs) in the matrix, the area fraction of the SPPs is more than 10 %. With the increase of Mo content, the population density of the SPPs increases significantly, while the average diameter of the SPPs decreases. Mo addition also affects the texture; the intensity of basal pole texture aligning normal direction decreases with the increase of Mo content in the alloys.Compared with Zr-4 and Zr–1Nb, Zr–1.0Cr–0.4Fe–xMo alloys have excellent corrosion resistance in 500 °C/10.3 MPa steam. The corrosion rates of Mo-containing alloys are higher than that of Mo-free alloy, which is mainly attributed to the solute Mo atoms in the Zr matrix.Change of the SPPs features due to the increase of Mo content alleviates the degradation of corrosion resistance in some degree, but it is not the dominant factor.     

Effects of cerium and manganese on corrosion of Fe–Cr and Fe–Cr–Ni alloys in Ar–20CO2 gas at 818 °C

Model alloys Fe–9Cr, Fe–20Cr and Fe–20Cr–20Ni (wt.%) with Ce (0.05%, 0.1%) or Mn (1%, 2%) were exposed to Ar–20CO₂ gas at 818 °C. Scales on Fe–9Cr alloys consisted of FeO and FeCr₂O₄, Fe–20Cr–(Ce) alloys formed only Cr₂O₃, and Fe–20Cr–(Mn) alloys formed Cr₂O₃ and MnCr₂O₄. All Fe–20Cr–20Ni alloys formed Fe₃O₄, FeCr₂O₄ and FeNi₃. Cerium additions had little effects, but additions of 2% Mn significantly improved oxidation resistance of Fe–20Cr and Fe–20Cr–20Ni alloys. Most alloys also carburized. All alloys developed protective chromium-rich oxide scales in air. Different behavior in the two gases is attributed to faster Cr₂O₃ scaling rates induced by CO₂.     

Effect of Co on oxidation and hot corrosion behavior of two nickel-based superalloys under Na2SO4–NaCl at 900 °C

Nickel-based superalloys with and without Co by partial replacement of W were prepared using double vacuum melting. A comparison of the oxidation in air and hot corrosion behaviors under molten 75wt.%Na₂SO₄+ 25wt.%NaCl at 900 °C were systematically investigated. The results showed that partial replacement of W with Co promoted the formation of chromia scale and consequently decreased the oxidation rate. Besides, the addition of Co also retarded the internal oxidation/nitridation of Al and consequently promoted the growth of Al₂O₃ scale, which further decreased the scaling rate and improved the adhesion of scale. Moreover, the addition of Co also further improved the hot corrosion resistance under molten Na₂SO₄–NaCl salts.     

The corrosion behavior of Fe-Al alloys in H2/H2S/H2O atmospheres at 700–900°C

The corrosion behavior of five Fe-Al binary alloys containing up to 40 at. % Al was studied over the temperature range of 700–900°C in a H₂/H₂S/H₂O mixture with varying sulfur partial pressures of 10^–7–10^–5 atm. and oxygen partial pressures of 10^–24–10^–2° atm. The corrosion kinetics followed the parabolic rate law in all cases, regardless of temperature and alloy composition. The parabolic rate constants decreased with increasing Al content. The scales formed on Fe-5 and –10 at.% Al were duplex, consisting of an outer layer of iron sulfide (FeS or Fe_1–xS) and an inner complex scale of FeAl₂S₄ and FeS. Alloys having intermediate Al contents (Fe-18 and –28 at.% Al) formed scales that consisted of mostly iron sulfide and Al₂O₃ as well as minor a amount of FeAl₂S₄. The amount of Al₂O₃ increased with increasing Al content. The Fe 40 at.% Al formed only Al₂O₃ at 700°C, while most Al₂O₃ and some FeS were detected at T800°C. The formation of Al₂O₃ was responsible for the reduction of the corrosion rates.     

Effects of Mo additions on the corrosion behavior of WC–TiC–Ni hardmetals in acidic solutions

The corrosion behavior of WC–TiC–Ni cemented carbides with the additions of molybdenum was investigated in 1 M H₂SO₄ and 1 M HCl solutions utilizing potentiodynamic polarization, long-term immersion tests and surface analytical techniques. The results show that the Mo additions can enhance the corrosion resistance of WC–TiC–Ni hardmetals owing to the formation of new (Ti, W, Mo)C phase based on TiC. Pseudopassivity was observed in the polarization curves of WC–Ni and WC–TiC–Ni hardmetals in HCl. However, the additions of molybdenum can make WC–TiC–Ni hardmetals passivated visibly in curves at 600 mV–1000 mV and enhance the pitting corrosion resistance due to the formation of MoO₃ film. In addition, all nickel based alloys show the typical passivation behavior in H₂SO₄ caused by the formation of NiSO₄, NiWO₄ and continuous metal oxide films.     

Oxidation behavior of a Zr–Cu–Al–Ni amorphous alloy in air at 300–425 °C

The oxidation behavior of Zr–30Cu–10Al–5Ni bulk metallic glass and its crystalline counterpart was studied over the temperature range of 300–425 °C in dry air. In general, the oxidation kinetics of both amorphous and crystalline alloys followed a two- or three-stage parabolic rate law at T⩾350 °C, while at 300 °C the amorphous alloy oxidized following a linear behavior. The oxidation rate constants for the amorphous alloy are slightly higher than those for the crystalline alloy at 350–400 °C. The scale formed on the amorphous alloy consists of mainly tetragonal-ZrO₂ at 300 °C, while a mixture of monoclinic-ZrO₂ (m-ZrO₂) and tetragonal-ZrO₂ (t-ZrO₂) and some CuO were detected at higher temperatures. The scale formed on the crystalline alloy, on the other hand, consists of mainly Al₂O₃, some tetragonal-ZrO₂, and a slight amount of monoclinic-ZrO₂ at 300 °C. At higher temperatures, the crystalline alloy consists of mainly monoclinic-ZrO₂, some CuO and Cu₂O, and limited tetragonal-ZrO₂. It is suggested that the formation of Al₂O₃ (at 300 °C) and CuO/Cu₂O (at 350-400 °C) on the crystalline alloy is responsible for the reduced oxidation rates as compared with those of amorphous alloy.     

Effect of water vapor on oxidation and creep behavior of incoloy 800 at temperatures between 850 and 980°C

The oxidation kinetics and creep behavior of Incoloy 800 were studied in air and in water vapor charged with oxygen. Oxidation kinetics were determined by thermogravimetry. The creep behavior of samples tested in air and in H₂OO₂=11 atmospheres was investigated by electron microscopic techniques. The oxidation rate of samples tested in air was governed by a p-conducting chromia interlayer. Depending upon water vapor pressure, chromia became n-conductive. As a consequence, a continuous rate-governing silica interlayer formed. The oxygen activity in the alloy was established by the dissociative pressure of the respective diffusion-rate-governing oxide scale. The stability of the dispersion-hardening Ti(C, N) particulates within the alloy was affected by the respective oxygen activity. In the samples tested in air, partial oxidation of the particulates due to enhanced oxygen activity caused a loss of coherency with the matrix. As a result, the deformation behavior during creep was changed to planar-slip mode, bringing about loss of creep resistance and ductility.     

Stress corrosion cracking at constant load of 304L stainless steel in molten NaCl-CaCl2 at 570°C

The incubation and propagation times of cracks in 304L in molten NaCl-CaCl₂ at 570°C were related to the applied stress value, from creep and creep rate curves. Rest potential versus time curves were recorded simultaneously. The results showed intergranular stress corrosion cracking. When the temperature was kept at 570°C, precipitation of chromium carbide M₂₃C₆ which promoted cracking propagation, was induced. Determination of the crack rate shows that anodic dissolution at the bottom of the cracks is the main process during the stress corrosion crack propagation of 304L stainless steel in the stress range used.     

Effect of TiC particles on the oxidation behavior of 2Cr13 stainless steel in a simulated marine environment at 550°C

In this study, the oxidation behavior of 2Cr13 stainless steels with/without TiC particles was investigated in a simulated marine environment at 550°C. The results showed that TiC particles greatly accelerated the oxidation rate of 2Cr13 steel during the cyclic oxidation reaction. At the same time, the effect of acceleration was alleviated by the small size and uniform distribution of TiC particles. As galvanic corrosion in the vicinity of TiC particles occurred in 3.5% NaCl solution spray, more NaCl particles deposited on the alloy surface, especially in the area around TiC particles. At 550°C, some shell-like oxidation products were generated on the 2Cr13 steel surface due to TiC addition, and then the porous oxidation products provided poor protective ability. Besides, the defect and stress in the oxide scale was reduced due to the small size and uniform distribution of TiC particles in 2Cr13 steel.     

Effect of phosphoric acid concentration on corrosion of Cr–Mn–N and Cr–Ni stainless steels

Phosphoric acid concentration (5–85%) effects on the corrosion behaviour of austenitic Fe–18Cr–12Mn–N steel have been studied by potentiodynamic polarisation measurements. After the anodic polarisation, both the film composition and the electronic structure have been investigated by X-ray photoelectron spectroscopy. The specimen surface examinations have been carried out by scanning electron microscopy. The results of the corrosion behaviour of the steel at issue have been compared to those relevant to two trademark materials [austenitic stainless steels AISI 304 (Fe–18Cr–9Ni) and X14AΓ15 (Fe–14Cr–15Mn–N)] and developed under the same test conditions.     

Effect of aluminium on the passivation of zinc–aluminium alloys in artificial seawater at 80 °C

The effect of Al (0.15, 0.3 and 1.0 wt.%) on the passivation of Zn–Al alloys in artificial seawater at 80 °C is investigated by electrochemical measurements, scanning electron microscopy (SEM) and X-ray diffraction (XRD). It is found that the presence of Al in Zn–Al alloys can retard passivation. Potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) measurements show that Al increases the current density but decreases the corrosion resistance of passive films, respectively. Mott-Schottky analysis reveals that Al increases the electrical conductivity and the capacitance of the films. Passivation of Zn–Al alloys occurs in artificial seawater when the immersion time is between 120 and 288 h, due to the presence of various Zn and Al protective compounds at the surfaces. Depassivation occurs when the immersion time is between 288 and 720 h, probably due to the decrease of solution pH and the Cl⁻ penetration mechanism.     

Effect of flow velocity on cavitation erosion behavior of HVOF sprayed WC-10Ni and WC-20Cr3C2–7Ni coatings

WC-10Ni and WC-20Cr₃C₂–7Ni coatings were deposited successively using high-velocity oxygen-fuel (HVOF) spraying. The microstructures and mechanical properties of the coatings were evaluated by X-ray diffraction (XRD), Field emission scanning electron microscopy (FESEM), energy dispersive X-ray spectroscopy (EDS), Vickers microhardness tester, and Ultra nanoindentation tester. The cavitation erosion behaviors of the coatings at different flow velocities were investigated by a rotating disk rig facility with bolt cavitator and circulating system. The results showed that the main phases in the WC-10Ni and WC-20Cr₃C₂–7Ni coatings were WC, W₂C, W, and WC, (W,Cr)₂C, respectively. Both coatings were dense and well bonded to the steel substrate. Despite higher porosity and elastic modulus (E) as well as slightly lower hardness (H), the WC-10Ni coating showed lower H/E, H³/E² and η values as well as cavitation erosion resistance at each flow velocity compared to the WC-20Cr₃C₂–7Ni coating. Both coatings exhibited an increase in the volume loss rates with increasing flow velocity, and the critical flow velocity of the WC-20Cr₃C₂–7Ni coating was in the region of 33.5 to 41.9 m·s⁻¹. The cavitation erosion failure mechanism of the WC-10Ni coatings was the brittle detachment of the WC particles, while cavitation pinholes, pits, cracks, craters, and massive exfoliation contributed to the evolution of the cavitation erosion processes of the WC-20Cr₃C₂–7Ni coating with the increase of the flow velocity.     

Fireside corrosion degradation of ferritic alloys at 600 °C in oxy-fired conditions

This paper reports the results of a study carried out to investigate the effects of simulated coal/biomass combustion conditions on the fireside corrosion. The 1000 h deposit recoat exposure (5 × 200 h cycles) was carried out at 600 °C. In these tests ferritic alloys were used 15Mo3, T22, T23 and T91. Kinetics data were generated for the alloys exposed using both traditional weight change methods and metal loss measurements. The highest rate of corrosion based on EDX results occurred under D1 deposit where provoke mainly by the formation of alkali iron tri-sulphate phase.     

Dynamic recrystallization behavior of Fe–20Cr–30Ni–0.6Nb–2Al–Mo alloy

Single-pass compression tests of an aluminaforming austenite(AFA) alloy(Fe–20Cr–30Ni–0.6Nb–2Al–Mo) were performed using a Gleeble-3500 thermal–mechanical simulator. By combining techniques of electron back-scattered diffraction(EBSD) and transmission electron microscopy(TEM), the dynamic recrystallization(DRX) behavior of the alloy at temperatures of 950–1100 ℃ and strain rates of 0.01–1.00 s~(-1) was investigated. The regression method was adopted to determine the thermal deformation activation energy and apparent stress index and to construct a thermal deformation constitutive model. Results reveal that the flow stress is strongly dependent on temperature and strain rate and it increases with temperature decreasing and strain rate increasing. The DRX phenomenon occurs more easily at comparably higher deformation temperatures and lower strain rates. Based on the method for solving the inflection point via cubic polynomial fitting of strain hardening rate(h) versus strain(e) curves, the ratio of critical strain(ec) to peak strain(ep) during DRX was precisely predicted. The nucleation mechanisms of DRX during thermal deformation mainly include the strain-induced grain boundary(GB)migration, grain fragmentation, and subgrain coalescence.     

Electrochemical corrosion behavior of Cu-40Ni-20Cr alloys with different grain sizes in solutions containing chloride ions

The electrochemical corrosion behavior of the two Cu-40Ni-20Cr alloys prepared by conventional casting（CA） and mechanical alloying（MA） with the different grain sizes was studied by using open-circuit potential（OCP）, potentiodynamic polarization and electrochemical impedance spectroscopy（EIS） methods in solutions containing chloride ions. The results show that the free corrosion potentials of the two alloys move towards negative values, corrosion currents increase and therefore corrosion rates become faster with the increase of chloride ion concentrations. EIS plots of CACu-40Ni-20Cr alloy are composed of single capacitive loop, while EIS plots of MACu-40Ni-20Cr alloy are composed of double capacitive loops in solution containing lower chloride ion concentrations. EIS plots of the two alloys have Warburg impedance with the increase of chloride ion concentrations. Corrosion rates of MACu-40Ni-20Cr alloy become faster than those of CACu-40Ni-20Cr alloy obviously in solutions containing the same chloride ion concentrations because MACu-40Ni-20Cr alloy is able to produce large concentrations of grain boundaries in the course of reduction in grain size by mechanical alloying.     

Effect of sulphides on corrosion of Cu–Ni–Fe–Mn alloy in sea water

Abstract

The corrosion behaviour of Cu–30Ni–2Fe–2Mn commercial alloy (similar to C71640) in quiescent, hermetically closed sulphide polluted and unpolluted natural sea water at 25°C was investigated. The corrosion resistance was examined using free corrosion and electrochemical tests and the surface film was characterised by chemical analysis and X-ray photoelectron spectroscopy. The different susceptibilities to corrosion were closely linked to the initial sulphide concentration; the accelerated attack occurring with an initial sulphide concentration of 4 ppm correlated with the amount of dissolved oxygen in solution and with the chemical composition of the corrosion layer.     

Oxidation of Two Ternary Cu–Ni–20 wt.% Cr Alloys at 700–800°C in 1 atm O2

Two ternary Cu–Ni–Cr alloys containing approximately 20 wt.% chromium, but with a different Cu and Ni content, have been oxidized in 1 atm of pure oxygen at 700–800°C. The alloy containing about 60 wt.% nickel (Cu–60Ni–20Cr) was composed of a single solid-solution phase and formed external scales of chromium ocide with an outermost layer containing a mixture of copper and nickel oxides. The alloy comprised of about 40 wt.% nickel (Cu–40Ni–20Cr) contained a mixture of two metal phases and formed complex external scales, containing copper oxide and a nickel–chromium spinel plus a region where islands of the metallic phase richer in chromium surrounded by a thin chromia layer were mixed with oxidized islands rich in copper and nickel, producing a situation out of equilibrium. With time, a very irregular and thin but essentially continuous layer of chromia formed at the base of the mixed internal region for this alloy, producing a gradual decrease of the corrosion rate down to very low values. The oxidation behavior of the two alloys is interpreted in terms of their different microstructure. In particular, the fast initial oxidation of Cu–40Ni–20Cr, associated with the formation of large amounts of copper oxides, is attributed to restrictions in chromium diffusion in the alloy due to the simultaneous presence of two metal phases.     

Effect of the Cr content on the sintering behaviour of TiCN–WC–Ni–Cr3C2 powder mixtures

In TiCN–W–Cr–Ni cermets produced by liquid phase sintering melting occurs at lower temperatures as their Cr content increases. For low Cr additions (up to 4 wt.%) eutectic temperatures are close to those found in the TiC–WC–Ni system. For 8 wt.% Cr and above, temperatures are similar to those found in the Cr–Ni–C system. The precipitation of M₇C₃ carbides is observed to start at 8 wt.% Cr in samples sintered at 1425 °C for 1 h. This sets a limit for the Cr solubility in the binder phase of these cermets around 18 wt.%. The dissolution of WC and Cr₃C₂ particles starts at temperatures as low as 1150 °C, but that the homogenization of the binder phase is only achieved after melting. The carbonitride phase exhibits the typical precipitation of inner and outer rims onto Ti(C,N) cores. However, a fine precipitation of Ni-rich particles is found inside Ti(C,N) cores, likely related to coalescence phenomena.     

Oxidation behavior of silicon carbide at 1200 °C in both air and water–vapor-rich environments

Oxidation of SiC in both air and water–vapor–rich environments was carried out at 1200 °C to examine the effects of different oxidation conditions on the early-stage oxidation behavior of SiC. Two different types of SiC oxidation behavior were found, passive or active, depending on the oxidation environment. All the samples possessed amorphous oxide layers, regardless of the oxidation environment. Three Si oxidation states (SiO, Si₂O₃, and SiO₂) were observed in this layer. The amorphous Si₂O₃ state was dominant, and the ratio of the three different states changed with the test conditions.