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High-Temperature, Dual-Atmosphere Corrosion of Solid-Oxide Fuel Cell Interconnects

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Abstract

High-temperature corrosion of ferritic stainless steel (FSS) surfaces can be accelerated and anomalous when it is simultaneously subjected to different gaseous environments, e.g., when separating fuel (hydrogen) and oxidant (air) streams, in comparison with single-atmosphere exposures, e.g., air only. This so-called “dual-atmosphere” exposure is realized in many energy-conversion systems including turbines, boilers, gasifiers, heat exchangers, and particularly in intermediate temperature (600–800°C) planar solid-oxide fuel cell (SOFC) stacks. It is generally accepted that hydrogen transport through the FSS (plate or tube) and its subsequent integration into the growing air-side surface oxide layer can promote accelerated and anomalous corrosion—relative to single-atmosphere exposure—via defect chemistry changes, such as increased cation vacancy concentrations, decreased oxygen activity, and steam formation within the growing surface oxide layers. Establishment of a continuous and dense surface oxide layer on the fuel side of the FSS can inhibit hydrogen transport and the associated effects on the air side. Minor differences in FSS composition, microstructure, and surface conditions can all have dramatic influences on dual-atmosphere corrosion behaviors. This article reviews high-temperature, dual-atmosphere corrosion phenomena and discusses implications for SOFC stacks, related applications, and future research.

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Acknowledgements

Portions of this work were supported by NASA-EPSCoR Grant #NNX09AP73A. Special thanks are given to the staff at Montana State University’s Image and Chemical Analysis Laboratory (ICAL) for assistance with the SEM/EDX analyses. Additional thanks to Jude Eziashi, Michael McCambridge, and McLain Leonard for assistance with experiments and data collection.

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  1. Department of Chemical Engineering, Montana State University, Bozeman, MT, 59717, USA

    Paul Gannon & Roberta Amendola

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  1. Paul Gannon
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  2. Roberta Amendola
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Correspondence to Paul Gannon.

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Gannon, P., Amendola, R. High-Temperature, Dual-Atmosphere Corrosion of Solid-Oxide Fuel Cell Interconnects. JOM 64, 1470–1476 (2012). https://doi.org/10.1007/s11837-012-0473-3

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