Long-Term Oxidation of Candidate Cast Iron and Stainless Steel Exhaust System Alloys from 650 to 800 °C in Air with Water Vapor

The oxidation behavior of candidate cast irons and cast stainless steels for diesel exhaust systems was studied for 5,000 h at 650–800 °C in air with 10 % H₂O. At 650 °C, Ni-resist D5S exhibited moderately better oxidation resistance than did the SiMo cast iron. However, the D5S suffered from oxide scale spallation at 700 °C, whereas the oxide scales formed on SiMo cast iron remained relatively adherent from 700 to 800 °C. The oxidation of the cast chromia-forming austenitics trended with the level of Cr and Ni additions, with small mass losses consistent with Cr oxy-hydroxide volatilization for the higher 25Cr/20–35Ni HK and HP type alloys, and transition to rapid Fe-base oxide formation and scale spallation in the lower 19Cr/12Ni CF8C plus alloy. In contrast, small positive mass changes consistent with protective alumina scale formation were observed for the cast AFA alloy under all conditions studied. Implications of these findings for exhaust system components are discussed.     

Improved Oxidation Resistance of a New Aluminum-Containing Austenitic Stainless Steel at 800 °C in Air

The oxidation resistance of austenitic stainless steels modified with various aluminum contents was investigated. The weight gain per unit area is in parabolic relation to oxidation time, and the oxidation rate significantly decreases with increased aluminum content. Outer layer oxides of austenitic stainless steel transform from Cr₂O₃ to a composite oxide layer comprising Cr and Al, and more dense Al-containing oxides formed with increasing the added Al contents. Since the diffusion of element Al is enhanced and the diffusion of element Cr is inhibited, the oxides enriched in Al dramatically contribute to the improved oxidation resistance of austenitic stainless steels at high temperature. The possible oxidation mechanisms are also proposed based on microstructural observations.     

High-Temperature Oxidation Behavior of SIMP Steel at 800 °C

In this work, the high-temperature oxidation behavior of SIMP and commercial T91 steels was investigated in air at 800 °C for up to 1008 h. The oxides formed on the two steels were characterized and analyzed by XRD, SEM and EPMA. The results showed that the weight gain and oxide thickness of SIMP steel were rather smaller than those of T91 steel, that flake-like Cr₂O₃ with Mn_1.5Cr_1.5O₄ spinel particles formed on SIMP steel, while double-layer structure consisting of an outer hematite Fe₂O₃ layer and an inner Fe–Cr spinel layer formed on T91 steel, and that the location of the oxide layer spallation was at the inner Fe–Cr spinel after 1008 h, which led the ratio between the outer layer and the inner layer to decrease. The reason that SIMP steel exhibited better high-temperature oxidation resistance than that of T91 steel was analyzed due to the higher Cr and Si contents that could form compact and continuous oxide layer on the steel.     

Oxidation Behavior of Tribaloy T-800 Alloy at 800 and 1,000 °C

The oxidation behavior of Co-based Tribaloy T-800 alloy has been studied isothermally in air at 800 and 1,000 °C, respectively. The results showed that the oxidation mechanism was dependent on the exposure temperature. The oxidation of the alloy followed subparabolic oxidation kinetics at 800 °C. The oxide scale at this temperature exhibited a multi-layered structure including an outer layer of Co oxide, a layer composed of complex oxide and spinel, a nonuniform Mo-rich oxide layer, an intermediate mixed oxides layer and an internal attacked layer with different protrusions into Laves phase. During 1,000 °C exposure, it followed linear kinetics. The oxidation rendered a relatively uniform external Cr-rich oxide layer coupled with a thin layer of spinel on the top surface and voids at local scale/alloy interface and intergranular region together with internal Si oxide at 1,000 °C.     

Evolution of Oxide Film of T91 Steel in Water Vapor Atmosphere at 750 °C

In order to investigate the evolution of oxide film on T91 steel, oxidation tests were conducted in water vapor atmosphere at 750 °C. The phase compositions and microstructures of the oxide scales for early stage oxidation were investigated by using glancing angle XRD and SEM equipped with EDS. The results showed that during the initial oxidation stage Cr-rich oxide film formed and then it covered the sample surface rapidly. The initial Cr-rich oxide film was mainly composed of FeCr₂O₄, (Fe,Cr)₂O₃ and Fe₂O₃. This oxide film acted as a barrier against outward diffusion of iron and inward diffusion of oxygen. During the initial oxidation stage, chromium in the sample surface was consumed gradually, and then a large amount of iron ions penetrated the oxide film and diffused rapidly to the sample surface, resulting in forming an outer “non-protective” Fe₂O₃ layer.     

Oxidation Behavior of Ni-3, 6 wt% Al Alloys at 800 °C in Atmospheres Containing Water Vapor

The oxidation behavior of Ni, Ni–3Al, and Ni–6Al alloys at 800 °C in air + H₂O was investigated. The oxidation kinetics of Ni and the alloys in air + H₂O were very similar, but the mass gains of Ni and each alloy were smaller in air + H₂O than in air. Oxidation products formed on Ni-3 and 6Al alloys consisted of an outer NiO scale and internal Al₂O₃ precipitates. The growth rates of both NiO and the internal oxidation zone were much smaller in air + H₂O. The NiO scale formed in air + H₂O was duplex in structure with outer porous and inner dense layers. The outer porous layer consisted of fine powder-like NiO particles. A thicker metallic Ni(Al) layer formed at the NiO/alloy interface in air + H₂O, caused by extrusion of Ni from the substrate due to volume changes accompanying the internal oxide formation. Formation of the metallic Ni layer appeared to be the reason for the similarity between the oxidation kinetics of both Ni and the alloys in air + H₂O.     

Pack Aluminide Coatings Formed at 650 °C for Enhancing Oxidation Resistance of Low Alloy Steels

THE COMMERCIAL ALLOY STEELS containingtypically9-12wt.%Cr and1wt.%Mo are low costmaterials developed for critical strength engineeringapplications at temperatures up to700°C[1-2].Thecomposition and microstructure of these materials arenormally optimised to provide the required mechanicalstrength and creep/fatigue resistance.However,thehigh temperature oxidation resistance is often notsufficient to prevent premature failure caused byoxidation degradation,particularly in high temperat…     

The Effect of NiAl Coatings on Oxidation Behavior of AISI 403 Stainless Steel

STAINLESS STEEL TYPE AISI403possess a highdegree of resistance to atmospheric corrosion becauseof its ability to form a dense adherent oxide film,whichprotects the material from further attack[1].Thiscomposition was developed to meet the requirementsfor some gas turbine components.The alloy is notparticularly recommended for use in hot corrosion andoxidation environments.Therefore,a protective coatinglayer is essential for such applications as hot sectioncomponents in gas turbine[2].A…     

The Effect of NiAI Coatings on Oxidation Behavior of AISI 403 Stainless Steel

This paper reports the oxidation behavior of stainless steel type 403 as a substrate material with and without NiAl coating. Evaluation of oxidation resistance was performed on uncoated and coated specimens at 850 and 1050℃. Acommercial diffusion process was used for the formation of NiA1 intermetallic coatings on the specimens. Before aluminizing, a layer of nickel, about 40μm, was deposited on specimens by electroplating. Various techniques including SEM, EDAX, optical microscopy and micro-hardness testing were employed to investigate the coatings before and after oxidation tests. Nickel-aluminides produced by two stage; plating-aluminizing, treatment with NiA1 on the surface increased the performance of stainless steel samples significantly.     

Water Vapour Effect on the Oxidation Mechanism of a Cobalt-Based Alloy at High Temperatures (800–1,100 °C)

A cobalt-based Phynox alloy was oxidized in the 800–1,100 °C temperature range. The alloy oxidation was consistent with a growth mechanism limited by the diffusion process in a growing Cr₂O₃ oxide scale. Water vapour enhanced the alloy oxidation rate and scale porosity. Thermal cycling tests at 900 and 1,000 °C showed that water vapour reduces the outer Mn_1.5Cr_1.5O₄ subscale adherence, but the chromia scale adherence was not affected. These temperatures permited a rapid chromium supply from the substrate to form a continuous chromia scale. At 1,100 °C thermal cycling conditions led to scale spallation and chromium depletion in the alloy. In dry air, weight losses were recorded due to cobalt and molybdenum oxidation, giving CoCr₂O₄ and CoMoO₄. In wet air, the initial porous chromia scale permited nickel and cobalt oxidation, leading to Ni₅Co₃O₈ and CoCr₂O₄ formation and resulting in bad adherence during thermal cycling.     

Pack Aluminide Coatings Formed at 650℃ for Enhancing Oxidation Resistance of Low Alloy Steels

This study aims to investigate the feasibility of forming iron aluminide coatings on a commercial 9Cr-1Mo (wt.%) alloy steel by pack cementation at 650℃ in an attempt to improve its high temperature oxidation resistance. Pack powders containing Al, Al2O3 and a series of halide salts were used to carry out the coating deposition experiments, which enabled identification of the most suitable activator for the pack aluminising process at the intended temperature. The effect of pack aluminium content on the growth kinetics and microstructure of the coatings was then studied by keeping deposition conditions and pack activator content constant while increasing the pack aluminium content from 1.4 wt.% to 6 wt.%. X-ray diffraction (XRD), scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) techniques were used to analyse the phases and microstructures of the coatings formed and to determine depth profiles of coating elements in the coating layer. Oxidation resistance of the coating was studied at 650 ~C in air by intermittent weight measurement at room temperature. It was observed that the coating could substantially enhance the oxidation resistance of the steel under these testing conditions, which was attributed to the capability of the iron aluminide phases to form alumina scale on the coating surface through preferential A1 oxidation.     

The Effect of Microstructural Evolution on Hardening Behavior of 2205 Stainless Steel in Long-Term Aging at 500 °C

The effect of microstructural evolution on hardening behavior of 2205 stainless steel in long-term aging at 500 °C was studied by optical microscope, scanning electron microscope, and transmission electron microscope. The results showed that the hardness of ferrite phase in matrix steadily increased with the aging time at the first stage of 4 months, presented a peak of hardness at about 5 months, and showed a downward trend for the aging time from 6 to 8 months, while the hardness of the austenitic phase remained constant. Analysis showed that the iron-rich α phase and the Cr-rich α′ phase generated by spinodal decomposition, Cr₂N precipitations, and Fe₂Mn (R-phase) were the main reasons for the generation of peak in hardness of ferrite phase. Further studies showed that some dislocation structure (changing with the aging time) in δ-ferrite of matrix is related to the microstructural evolution.     

Lanthanum Effect on the Isothermal High Temperature Oxidation Behavior at 1,000 °C of a Phosphoric Acid-Treated AISI 304 Stainless Steel

Many studies have shown that a phosphoric-acid treatment improves the high temperature oxidation resistance in air of some alloys. Interestingly, though, the phosphoric-acid treatment generates a structural modification of the steel surface which is catastrophic for the high-temperature oxidation behavior at 1,000 °C. The aim of our work was to test the effect of a reactive element sol–gel coating on high-temperature oxidation resistance of phosphoric acid-treated AISI 304 steel. The oxide scale growth mechanisms were studied by exposing La-coated and uncoated phosphoric acid-treated 304 steel samples to high-temperature conditions in air. A phosphoric-acid treatment modified the structural composition and the surface morphology of the AISI 304 steel by the formation of a FeH₂P₃O₁₀ structure, leading to hematite formation and to a breakaway phenomenon. Lanthanum coating, after initial phosphoric-acid treatment, led to the formation of LaCrO₃ which limited through-scale cracking and reduced the growth of iron oxides.     

Iron Oxidation at Low Temperature (260–500 °C) in Air and the Effect of Water Vapor

The oxidation of iron has been studied at low temperatures (between 260 and 500 °C) in dry air or air with 2 vol% H₂O, in the framework of research on dry corrosion of nuclear waste containers during long-term interim storage. Pure iron is regarded as a model material for low-alloyed steel. Oxidation tests were performed in a thermobalance (up to 250 h) or in a laboratory furnace (up to 1000 h). The oxide scales formed were characterized using SEM-EDX, TEM, XRD, SIMS and EBSD techniques. The parabolic rate constants deduced from microbalance experiments were found to be in good agreement with the few existing values of the literature. The presence of water vapor in air was found to strongly influence the transitory stages of the kinetics. The entire structure of the oxide scale was composed of an internal duplex magnetite scale made of columnar grains and an external hematite scale made of equiaxed grains. ¹⁸O tracer experiments performed at 400 °C allowed to propose a growth mechanism of the scale.     

Effect of Shot Blasting on Oxidation Behavior of TP304H Steel at 610℃-770℃ in Water Vapor

Shot blasting on a tube steel of TP304H can greatly improve the oxidation resistance at 650℃-770℃ in water vapor, by the presence of an appropriate blasting intensity. SEM and EPMA analysis indicated that the structure of the oxide scale turned from multi-layer to monolayer after blasting and Cr2O3 in predominant. The untreated sample characterized in multi-layer oxide was composed of Fe in the outer layer and Fe and Cr underneath. For blasted one, the increase of diffusion rate of Cr and the decrease of effective diffusion energy of scale led to a uniform Cr-rich oxide layer, which was dense and protective and the oxidation resistance was increased.     

High Temperature Oxidation Behavior of High Speed Steel for Roll in Water Vapor

The oxidation behavior of high speed steel (HSS) was researched by high temperature thermo balance at 500 to 800℃ in water vapor. The morphology was observed by scanning electron microscope, the microstructure of oxide scale was analyzed by energy dispersive spectrometer and X-ray diffraction spectrum. The results indicate that the mass gain of HSS increases with oxidation temperature rising, the effect of oxidation temperature on the morphology is obvious, water vapor temperature only affects mass gain and affects hardly morphology of oxide scale at the same oxidation temperature. The relevant oxidation mechanisms are also discussed.     

Effect of Shot Blasting on Oxidation Behavior ofTP304H Steel at 610℃-770℃ in Water Vapor

THE TP304H steel with19wt%Cr was designed toform a Cr2Os layer to keep from vapor attack atelevated temperature.However,the TP304H steel waseasy to be oxidized and covered with iron oxide withina short period of time in the working environment m.The investigation found that if the vapor temperaturewere not high enough to ensure the transportation rateof Cr atoms,the concentration of Cr in the oxidizedlayer would be too low to form a protective scale.Minami applied shot blasting(SB)on the…     

Characterization of Oxide Scales Formed on Ferritic Stainless Steel 441 at 1,100 °C under water vapor

This study focuses on the characterization of the oxide scales formed after different exposure times in the range of 2.5–20 min. A commercially available ferritic steel grade AISI 441 was exposed to wet argon at 1100 °C with 5, 9 and 13% H₂O. Raman microspectroscopy, XRD, EDS and XPS were used to fully characterize the oxide scale. For all samples exposed for over 4 min, the scale was constituted of three layers in this order: a thin top layer of spinel phases (Fe,Cr,Mn)₃O₄ with local outgrowths; a second and main layer of Cr₂O₃ + (Mn,Cr)₃O₄; and finally a bottom layer of SiO₂. The uncommon presence of Fe in the top layer was also observed.     

Effect of Yttrium as Alloying Element on a Model Alumina-Forming Alloy Oxidation at 1100 °C

In order to study the effect of yttrium as alloying element on the high-temperature oxidation of an alumina-forming alloy, 0.093 wt% yttrium was incorporated into a model FeCrAl alloy. Yttrium has a beneficial effect on the isothermal oxidation behavior in air at 1100 °C. Glancing angle X-ray diffraction made on a sample oxidized for 1000 h under thermal cycling conditions indicated that yttrium is located at the internal interface as Y₃Al₅O₁₂. Secondary neutral mass spectrometry results showed that the diffusion mechanism is modified by the presence of yttrium as an alloying element. Moreover, the beneficial effect of yttrium on the alloy oxidation is also related to a reduced metallic grain size. The growth of metal grains during oxidation was especially observed on the yttrium-free FeCrAl alloy. It is also well established that the diffusion mechanism in the oxide scale is modified by yttrium. The aim of the present work was to show that yttrium also plays a role on the aluminum diffusion in the metallic substrate and has a strong influence on the kinetic transient stage during the FeCrAl–0.1Y oxidation.