Metal Dusting of Fe–Cr and Fe–Ni–Cr Alloys Under Cyclic Conditions

Metal dusting is the disintegration of alloys into carbon and metal particles during high-temperature exposure to carbon-bearing gases. Model Fe–Cr and Fe–Ni–Cr alloys were studied to test the hypothesis that M₃C formation is necessary for metal dusting to occur. The alloys were exposed to a 68% CO–26% H₂–6% H₂O gas mixture at 680°C (a_c=2.9) under thermal cycling conditions. Equilibrium calculations predicted the formation of M₃C at the surface of Fe–25Cr, but not Fe–60Cr. All compositions were expressed in w/o, weight percent. Alloys of Fe–25Cr with 2.5, 5, 10, and 25 w/o nickel additions were also exposed to the same conditions to study the role of nickel in destabilizing the precipitation of M₃C and, hence, altering the resistance to metal dusting. Metal dusting was observed on all the alloys except Fe–60Cr. For Fe–25Cr, Fe–25Cr–2.5Ni, and Fe–25Cr–5Ni, the carbonization and dusting process was localized, and its incidence decreased in Fe–25Cr–2.5Ni, consistent with the increased destabilization of M₃C precipitation. However, Fe–25Cr–10Ni and Fe–25Cr–25Ni both underwent extensive dusting in the absence of protective Cr₂O₃ formation. The carbon deposits formed consisted of carbon filaments, which contained particles at their tips. These were shown by electron diffraction to be exclusively Fe₃C in Fe–25Cr, Fe–25Cr–2.5Ni, and Fe–25Cr–5Ni, and a mixture of austenite and (Fe,Ni)₃C in Fe–25Cr–10Ni and Fe–25Cr–25Ni.