Temperature dependence of oxide scale formation on high-Cr ferritic steels in Ar–H2–H2O

Four high chromium ferritic steels were oxidized in Ar/H₂/H₂O at temperatures between 500 and 900 °C. Polished specimens of all steels formed iron-rich oxides at temperatures below 600 °C, whereas increasing the temperature resulted in local formation of protective chromia scales. As the temperature was raised further, the specimens were totally covered with chromia scales. For the higher chromium steels this was also observed at 900 °C but not for the steel with a chromium content of 16%. The temperature dependence of the oxidation rates is governed by the competing diffusion processes in the alloy and the growing scales.     

Stochastic process corrosion growth models for pipeline reliability

Linear random variable corrosion models are extensively employed in reliability analysis of pipelines. However, linear models grossly neglect well-known characteristics of the corrosion process. Herein, a non-linear model is proposed, where corrosion rate is represented as a Poisson square wave process. The resulting model represents inherent time-variability of corrosion growth, produces continuous growth and leads to mean growth at less-than-one power of time. Different corrosion models are adjusted to the same set of actual corrosion data for two inspections. The proposed non-linear random process corrosion growth model leads to the best fit to the data, while better representing problem physics.     

Three dimensional microstructure study of oxide scale formed on a high-speed steel by means of SEM, FIB and TEM

Characteristics of the oxide scale formed on a high-speed steel (HSS) material in the temperature range 550–650 °C were examined. The surface morphologies of oxidised sample indicate that the temperature has a significant influence on the oxidation behaviour of the HSS samples. Differential oxidation is expected to occur due to high-alloyed components in the material. The carbide-free matrix has a good oxidation resistance due to the dissolved chromium; while vanadium rich carbide (MC) regions were oxidised heavily because of high free energy at the carbide/matrix interface and low thermal stability of the MC carbides. FIB/TEM cross-section observation shows that the oxide scale formed on the surface has a duplex-layer structure with vanadium oxides covering the top of the scale.     

A method of probabilistic analysis for steel pipeline with correlated corrosion defects

A method of probabilistic analysis is presented to consider effect of correlation of corrosion defects on steel pipeline failure. Failure probability of pipeline with correlated corrosion defects is modeled and compared with results from conventional method. The results showed that assumption of independent corrosion defects will lead to conservative results. The calculated results are within Ditlevsen bimodal bounds. This indicates the validity and feasibility of the proposed method. The combined effect of both the model sensitivity of prediction to variables and the uncertainty of variables should be taken into account in sensitivity analysis.     

A simple model for the oxidation of carbon-containing composites

The isothermal oxidation mechanism of the carbon-containing composites has been investigated based on the experimental data reported in the literature. The results showed that the oxidation kinetics was affected not only by temperature and time but also by carbon content and the sample shape. For the oxidation kinetics, a series of quantitative kinetic models have been developed based on the controlling step. In this model, the effects of carbon content, sample size and temperature on the reaction fraction have been especially discussed. Incorporation of the experimental data into the new model indicates that a good agreement has been reached.     

Experimental study and modeling of high temperature oxidation of Nb-base in situ composites

The oxidation behavior of Nb-base in situ composites in static air at 1100, 1200 and 1250 °C has been studied. The reaction followed the parabolic rate law. The oxide scales were mainly composed of TiNb₂O₇, TiNb₁₀O₂₉, TiO₂, Nb₂O₅ and SiO₂. The theoretical oxidation model proposed by Gesmundo et al. has been applied to analyze existing oxidation data of Nb-base in situ composites. The result shows that oxidation rate of the Nb-base in situ composites is basically accordance with the analytical results predicted by the theoretical oxidation model to a good approximation.     

Modeling pitting corrosion by means of a 3D discrete stochastic model

Pitting corrosion is difficult to detect, predict and design against. Modeling and simulation can help to increase the knowledge on this phenomenon as well as to make predictions on the initiation and progression of it. A cellular automaton based model describing pitting corrosion is developed based on the main mechanisms behind this phenomenon. Further, a sensitivity analysis is performed in order to get a better insight in the model, after which the information gained from this analysis is employed to estimate the model parameters by means of experimental time series for a metal electrode in contact with different chloride concentrations.     

Probabilistic analysis of pipelines with corrosion defects by using FITNET FFS procedure

A probabilistic method based on the corrosion module of the FITNET FFS procedure is presented to perform the structural integrity analysis for pipelines. The comparison of the failure pressure determined by both deterministic and probabilistic methods shows that even for a high safety factor, the deterministic method may predict nonconservative results. FITNET FFS procedure predicts a similar probability to that given by the Shell-92 model. The sensitivity analysis of both the uncertainty of the variables and the underlying model shows that the corrosion depth has the most significant contribution to the pipeline failure at an inspection interval of 8 years.     

Effect of yttrium addition on the oxide scale of AM50 magnesium alloy

This paper focused on the effect of yttrium (Y) addition on oxidation resistance of AM50 alloy. The oxide scale on the surface was studied. Elemental Y in solid solution played an important role in improvement of oxidation resistance and formation of oxide scale. Yttrium (0.28 wt%) addition in AM50 alloy could greatly enhance the oxidation resistance. Furthermore, with increasing Y addition, the scale/substrate adherence was increased. However, when Y addition exceeded 0.28 wt%, it was decreased.     

Experimental studies and modeling of the oxidation of multiphase niobium-base alloys

A three-phase oxidation model has been developed for study the oxidation behavior of multiphase alloys. This model has been utilized to identify the oxidation behavior of three-phase Nb-base alloys and successfully predicted the critical value for the exclusive formation of CrNbO₄. It has shown that the exclusive formation of CrNbO₄ on the Nb-base alloys can be achieved by the volume fraction increasing and the particle size decreasing for NbCr₂ phase. Moreover, the barrier effect of Nb₅Si₃ phase on the diffusion of Cr in Nb-base alloys has also been deduced in this work.     

On the oxidation mechanism of Ni–Pt alloys at high temperatures

The oxidation mechanism of Ni–Pt alloys has been studied as a function of alloy composition, oxygen pressure and temperature. It has been found that the oxidation rate of all the alloys follows the parabolic rate law, being thus diffusion controlled. In agreement with Wagner’s theory, the slowest step of the overall oxidation rate of alloys with higher nickel content (?40 at.%) is determined by the outward diffusion of nickel cations in the growing NiO scale. On the other hand, the oxidation rate of alloys with a lower nickel content (<40 at.%) is governed by the solid state diffusion in the metallic phase.     

Vacancy mechanism of oxygen diffusivity in bcc Fe: A first-principles study

Diffusivity of interstitial oxygen (O) in bcc iron (Fe) with and without the effect of vacancy has been investigated in terms of first-principles calculations within the framework of transition state theory. Examination of migration pathway and phonon results indicates that O in octahedral interstice is always energetically favorable (minimum energy) with and without vacancy. It is found that vacancy possesses an extremely high affinity for O in bcc Fe, increasing dramatically the energy barrier (∼80%) for O migration, and in turn, making the predicted diffusion coefficient of O in bcc Fe in favorable accord with experiments.     

Comparison of uniform and non-uniform corrosion induced damage in reinforced concrete based on a Gaussian description of the corrosion layer

A Gaussian function is proposed to describe the non-uniform spatial distribution of corrosion products as measured from chloride-exposed reinforced concrete specimens using backscattered electron imaging and image analysis. The model provides a good fit to the observed data and limited data sets reported in the literature. Subsequently, it is used as an input into a finite element analysis to provide a qualitative comparison of the damage induced on concrete from idealized uniform corrosion and more realistic non-uniform corrosion. The spatial distribution of corrosion is shown to have a major impact on the propagation phase, directly influencing residual service life.     

Pitting corrosion in low carbon steel influenced by remanent magnetization

A new type of experiment is performed using a closed magnetic circuit configuration in order to study the influence of the magnetic field on pitting corrosion in low carbon pipeline steel. The statistical assessment of the pitting corrosion data shows that the magnetic field in the material under test reduces the extreme pit depths and also the average depth of the pit population. It is proposed that reduction in pit depth under the influence of remanent magnetization can be explained based on the behavior of the paramagnetic corrosion products under the influence of the magnetic field gradient produced inside pits.     

Effect of Dy on oxide scale adhesion of NiAl coatings at 1200 °C

The cyclic oxidation behaviour of β-NiAlDy coatings produced by electron beam physical vapour deposition (EB-PVD) was investigated. For the Dy-free NiAl coating, numerous voids developed at the Al₂O₃ scale/NiAl interface and sulfur was found to segregate at the void surfaces, leading to early spallation of the scale. The addition of Dy prevented sulfur segregation and void formation at the scale/NiAl interface. As a result, the scale grown on the NiAlDy coating remained adherent and no spallation occurred even after 400 h cyclic oxidation. The 0.05 at.% Dy doped coating revealed lower oxidation rate than the more Dy doped coatings.     

Effect of yttrium on the oxide scale adherence of pre-oxidized silicon-containing heat-resistant alloy

This paper investigates the effect of the rare earth element yttrium on the rupture behaviour of the oxide scale on the silicon-containing heat-resistant alloy during cooling. After 10 h of oxidation, yttrium is found to facilitate the formation of internal oxides (silica) at the scale–matrix interface. Due to the twinning observed by scanning transmission electron microscopy (STEM) in silica, the critical strain value for the scale failure can be dramatically improved, and the formation of cracks at the scale–matrix interface is inhibited.     

Predicting the mechanisms and crack growth rates of pipelines undergoing stress corrosion cracking at high pH

A fundamentally based mathematical model was developed with the goal to predict, as a first step, the crack growth rate (CGR) of high pH stress corrosion cracking (SCC) of buried steel pipelines. Two methods were used to predict CGRs and for both methods the model has included the film rupture and repassivation mechanism. The two methods are distinguished by the expression used to determine the active anodic current density at the crack tip. In the first method, this current density is expressed by the anodic polarization curve with a large peak current density and the prediction tends to yield a larger CGR and a lower pH at the crack tip. By contrast, when the Butler–Volmer equation is used to express the crack tip anodic current density, with a predicted low CGR the chemistry at the tip does not appear to have any significant change due to the high buffer of the solution.The predicted mechanism responsible for the steady-state crack growth is shown to be the balance between the increasing stress intensity factor as the crack grows, which tends to increase the crack tip strain rate and thus the CGR, and the change of the crack tip condition, which, for large CGRs, is the significant shift in the more negative direction of the crack tip potential, and for low CGRs, the increase of ferrous ion concentration, and either tends to decrease CGR.Limitations currently existing in the model and proposal for further development of the model are discussed.     

The growth mechanism of CO2 corrosion product films

Carbon steel usually has high corrosion rate in water with dissolved CO₂ however the steel surface can be covered by protective corrosion product film. Therefore the carbon steel can be widely used in oil and gas industry. This paper discusses the structure, electrochemistry performances, initiation and growth of protective corrosion product films. A duplex layer structure of FeCO₃ films was found by electrochemical impedance spectrum (EIS). The physical and chemical situations of solution near carbon steel surface were investigated by ultraviolet spectrophotometry and chronopotentiometry. According to crystallography the growth mechanisms of protective CO₂ corrosion product films were discussed.     

Quantification of growth kinetics and adherence of oxide scales formed on Ni-based superalloys at high temperature

Cyclic and isothermal oxidation behaviors of first and fourth-generation superalloys AM1 and MCNG were investigated to evaluate the ability of the scratch test to quantify the adhesion of multi-layered oxide scales. Effects of sulfur content and of scale thickness were studied independently. Available models lead to large discrepancies in the calculated work of adhesion values with the evaluation of the residual stress being the largest source of error. Nevertheless, models can assess the effect of sulfur content and the scratch test can be used to correlate the long-term cyclic oxidation behavior and the adhesion of oxide scales.     

The oxidation kinetics of multi-walled carbon nanotubes

The kinetics of isothermal oxidation of multi-walled carbon nanotubes (MWNTs) in air has been investigated in the experimental range of 573-823 K using thermogravimetry. The results show that the oxidation of MWNTs is both chemically controlled and diffusion controlled depending on the temperature range. Chou’s model has been applied to treat the oxidation behavior of MWNTs and the comparison of the experimental data with the theoretical ones validates the applicability of the model. This model offers a quantitative expression for the weight loss as a function of time at constant temperature conditions. The possible mechanism for oxidation has also been discussed briefly.