Overview of Strategies for High-Temperature Creep and Oxidation Resistance of Alumina-Forming Austenitic Stainless Steels

A family of creep-resistant, alumina-forming austenitic (AFA) stainless steel alloys is under development for structural use in fossil energy conversion and combustion system applications. The AFA alloys developed to date exhibit comparable creep-rupture lives to state-of-the-art advanced austenitic alloys, and superior oxidation resistance in the ~923 K to 1173 K (650 °C to 900 °C) temperature range due to the formation of a protective Al₂O₃ scale rather than the Cr₂O₃ scales that form on conventional stainless steel alloys. This article overviews the alloy design approaches used to obtain high-temperature creep strength in AFA alloys via considerations of phase equilibrium from thermodynamic calculations as well as microstructure characterization. Strengthening precipitates under evaluation include MC-type carbides or intermetallic phases such as NiAl-B2, Fe₂(Mo,Nb)-Laves, Ni₃Al-L1₂, etc. in the austenitic single-phase matrix. Creep, tensile, and oxidation properties of the AFA alloys are discussed relative to compositional and microstructural factors.