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On the Reaction Mechanism of MCrAlY Alloys with Oxide–Sulfate Deposits at 1100 °C

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Abstract

The corrosion of γ-(Ni,Co) + β-(Ni,Co)Al NiCoCrAlY alloys exposed to CaO-rich, Na2SO4-containing deposits in air and CO2–H2O–O2 at 1100 °C was studied with a focus on the mechanisms governing the accelerated attack of γ-rich compositions. Internal oxidation of Al resulted from the breakdown of an initially formed Al2O3 scale, due to its reaction with the deposit. Compared to deposit-free conditions, this scale exhibited: (i) a delayed Al2O3 structure transition from metastable θ to stable α; (ii) finer grains; (iii) a reduced adherence to the metal, to the extent that a gap developed at the metal/oxide interface; and (iv) significant permeability to S, as well as N during air exposures. The occurrence of sulfidation in S-free gases reflected the establishment of an elevated S activity under the molten Na2SO4, due to the locally reduced \(p_{{{\text{O}}_{ 2} }}\). The factors affecting the Al2O3-scale microstructure were examined, as well as the associated consequences on Al consumption and on the transition to internal oxidation. The roles of alloy and gas compositions in the identified mechanisms were also discussed.

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Acknowledgments

This work was supported by the Department of Energy through the University Turbine Systems Research (UTSR) Program run by the National Energy Technology Laboratory, award number DE-FE0007271, and Seth Lawson, Project Manager. The authors thank Maryam Zahiri Azar and Arthur Heuer (Case Western Reserve University), as well as Susheng Tan (University of Pittsburgh), for the FIB and TEM work.

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  1. Thomas Gheno

    Present address: DEN-Service de la Corrosion et du Comportement des Matériaux dans leur Environnement, CEA, Université Paris-Saclay, 91191, Gif-sur-Yvette, France

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  1. Department of Mechanical Engineering and Materials Science, University of Pittsburgh, Pittsburgh, PA, 15261, USA

    Thomas Gheno & Brian Gleeson

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Correspondence to Thomas Gheno.

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Gheno, T., Gleeson, B. On the Reaction Mechanism of MCrAlY Alloys with Oxide–Sulfate Deposits at 1100 °C. Oxid Met 86, 385–406 (2016). https://doi.org/10.1007/s11085-016-9649-5

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