The Corrosion of Cu–Al Binary Alloys in H2/H2S/H2O Atmospheres at 400–900°C

The corrosion behavior of pure Cu and of three Cu–Al alloys containing 1, 5, and 10 wt.% Al was studied at 400–900°C in a H₂/H₂S/H₂O gas mixture. Both Cu–1Al and Cu–5Al alloys had the single-phase structure of α-Cu, while Cu–10Al was the intermetallic compound Cu₃Al. In general, the corrosion behavior of all the alloys followed the parabolic rate law, and the corrosion rate constants generally increased with increasing temperature but decreased with increasing Al content. The scale formed on pure Cu was an exclusive single layer of Cu₂S, while the scales formed on Cu–Al alloys were heterophasic and duplex, consisting of an outer layer of Cu₂S and an inner layer of Cu₂S and CuAlS₂. X-ray diffraction results showed no evidence of oxides and the amount of CuAlS₂ increased with increasing Al content. The formation of Cu₂S and CuAlS₂ on higher Al-content alloys resulted in a subsurface phase transformation from α-Cu (for Cu–5Al) or from Cu₃Al (for Cu–10Al) to Cu₃Al + Cu₉Al₄. The formation of CuAlS₂ in the inner layer of Cu–Al alloys was responsible for the reduction of corrosion rates, as compared to those of pure Cu.