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Comparative Study of FeCrAlY and Sapphire Hot Corrosion by Mixed Oxide and Sulfate Deposits

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Abstract

Alloys and oxidation-resistant coatings utilized in high-temperature applications can be degraded by aerosols that deposit onto surfaces during operation. Understanding how the deposit composition influences the hot corrosion mechanisms is essential to develop more durable materials. This work advances the understanding of the effect of complex oxide and sulfate deposits on the degradation of an alumina-forming FeCrAlY alloy in comparison to reactions with single-crystal sapphire. The deposit compositions were developed to systematically understand the effect of anion makeup (mixed oxides, oxide–sulfate, and sulfates) and the effect of adding Na and K salts. CaSO4 was used as a control. The mixed oxide and oxide–sulfate deposits increased the frequency of thermally grown oxide (TGO) intrusions in FeCrAlY but did not produce a noticeable change in the sapphire. Pure CaSO4 and mixed sulfate reacted with the TGO and sapphire to form calcium aluminates and led to roughening of the specimen–reaction product interface. The primary difference between the CaSO4 and mixed sulfate deposits was the increased uniformity of the attack by the latter due to its tendency to melt and spread. Comparison between the change in the degradation features in the presence of CaSO4 and mixed sulfate deposits on both types of specimens expands the current understanding of sulfate-based hot corrosion.

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Acknowledgements

The authors are grateful to Drs. Pin Lu, Changning Niu, and Jiadong Gong (QuesTek Innovations LLC) for the insightful discussions, and to Dr. Eeshani Godbole for assistance preparing the deposit powders.

Funding

This research was supported by the Office of Naval Research (Award number N68335-20-C-0472 monitored by Dr. David Shifler) in collaboration with QuesTek Innovations LLC. Part of this work was carried out in the Characterization Facility, College of Science and Engineering, University of Minnesota, which receives support from the National Science Foundation through the MRSEC (Award Number DMR-2011401) and the NNCI (Award Number ECCS-2025124) programs.

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Authors and Affiliations

  1. Department of Chemical Engineering and Material Science, University of Minnesota, Minneapolis, USA

    Atharva S. Chikhalikar & David L. Poerschke

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  1. Atharva S. Chikhalikar
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  2. David L. Poerschke
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Contributions

Both authors designed the study. AC performed the experiments, characterization, and initial data analysis, prepared the figures, and wrote the first draft of the manuscript. DP contributed to data interpretation and edited the figures and manuscript. Both authors reviewed the final manuscript.

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Correspondence to David L. Poerschke.

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Chikhalikar, A.S., Poerschke, D.L. Comparative Study of FeCrAlY and Sapphire Hot Corrosion by Mixed Oxide and Sulfate Deposits. High Temperature Corrosion of mater. 100, 321–344 (2023). https://doi.org/10.1007/s11085-023-10182-2

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