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Evaluation of the Corrosion Resistance of Fe–Al–Cr Alloys in Simulated Low NO x Environments

Part 1: Corrosion Exposures and Scanning Electron Microscopy

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Abstract

Due to their excellent corrosion resistance, iron aluminum alloys are currently being considered for use as weld claddings in fossil fuel fired power plants. The susceptibility to hydrogen cracking of these alloys at higher aluminum concentrations has led researchers to examine the effect of chromium additions on the corrosion resistance of lower aluminum alloys. In this work, three iron aluminum alloys were exposed to simulated coal combustion environments at 500 and 700 °C for short (100 h) and long (5000 h) isothermal durations. Scanning electron microscopy was used to analyze the corrosion products. All alloys exhibited excellent corrosion resistance during short term exposures. For longer test times, increasing the aluminum concentration improved alloy corrosion resistance. The addition of chromium to the binary iron aluminum alloy prevented the formation iron sulfide and resulted in slower corrosion kinetics. A general classification of the scales developed on these alloys is presented.

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Acknowledgments

This work was supported by the Department of Energy through the National Energy Technology Laboratory through grant number DE-FG26-04NT42169. The authors wish to thank Dr. Vinod Sikka of Oak Ridge National Laboratory for preparation of the alloys used in this study.

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Authors and Affiliations

  1. Materials Science and Engineering Department, Lehigh University, 5 East Packer Avenue, Bethlehem, PA, 18015, USA

    R. M. Deacon, J. N. DuPont, C. J. Kiely & A. R. Marder

  2. Johns Hopkins University Applied Physics Laboratory, 11100 Johns Hopkins Road, Laurel, MD, 20723, USA

    R. M. Deacon

  3. Oak Ridge National Laboratory, P.O. Box 2008, Oak Ridge, TN, 37831, USA

    P. F. Tortorelli

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  1. R. M. Deacon
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  2. J. N. DuPont
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  3. C. J. Kiely
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  4. A. R. Marder
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  5. P. F. Tortorelli
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Correspondence to R. M. Deacon.

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Deacon, R.M., DuPont, J.N., Kiely, C.J. et al. Evaluation of the Corrosion Resistance of Fe–Al–Cr Alloys in Simulated Low NO x Environments. Oxid Met 72, 67–86 (2009). https://doi.org/10.1007/s11085-009-9148-z

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  • DOI: https://doi.org/10.1007/s11085-009-9148-z

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