Abstract
Long-term cyclic oxidation testing was conducted on oxide dispersion strengthened (ODS) and cast FeCrAlY alloys at 1100 and 1200 °C with 1 or 100 h hold time in air, O2, and humid atmospheres. These data were used to optimize four different cyclic oxidation models and calculate the Al consumption rate due to oxidation. The pkp and COSIM-GSA models were able to reproduce accurately the experimental oxidation curves, and lifetime predictions based on these models were in good agreement with experiments. Microstructure characterization revealed that the degradation of the ODS FeCrAlY cyclic oxidation performance was mainly due to the incorporation of Ti carbonitrides in the alumina scale and the formation of tensile cracks. Controlling the levels of C, N, and S in one ODS alloy resulted in oxidation performance only moderately lower than the performance of cast FeCrAlY alloys. A few, very deep, tensile cracks formed at the cast alloy surface upon thermal cycling. Finally, the effect of specimen mechanical strength and the presence of H2O on ODS FeCrAl durability are discussed.
Similar content being viewed by others
References
B. K. Kad, S. Dryepondt, A. R. Jones, V. Cedro III, G. J. Tatlock, B. A. Pint, P. F. Tortorelli, and P. A. Rawls, Proceedings of the 8th International Charles Parsons Turbine Conference, Portsmouth (2011).
J. D. Whittenberger, Metallurgical Transactions A 12, 845–851 (1981).
C. L. Chen, P. Wang and G. J. Tatlock, Materials at High Temperatures 26, 299–303 (2009).
I. Gurrappa, S. Weinbruch, D. Naumenko and W. J. Quadakkers, Materials and Corrosion 51, 224–235 (2000).
W. J. Quadakkers and K. Bongartz, Materials and Corrosion 45, 232–241 (1994).
H. Al-badairy, G. J. Tatlock and M. J. Bennett, Materials at High Temperatures 17, 101–107 (2000).
B. A. Pint, L. R. Walker and I. G. Wright, Materials at High Temperatures 21, 175–185 (2004).
M. J. Bennett, R. Perkins, J. B. Price, F. Starr, Proceedings of the 10th Conference on Materials for Advanced Power Engineering, eds. D. Coutsouradis et al., Vol. 1553 (Kluwer Academic Publishers, Liege, October 1994).
M. J. Bennett, Solid State Phenomena 41, 235–252 (1995).
C. E. Lowell, C. A. Barrett, R. W. Palmer, J. V. Auping and H. B. Probst, Oxidation of Metals 36, 81–112 (1991).
I. G. Wright, B. A. Pint, L. M. Hall and P. F. Tortorelli, in Lifetime Modelling of High Temperature Corrosion Processes, eds. M. Schütze, W. J. Quadakkers and J. R. Nicholls, Vol. 34 (Maney Publishing, London, 2001) pp. 338–358.
J. R. Nicholls, R. Newton, M. J. Bennett, H. E. Evans, H. Al-Badairy, G. J. Tatlock, D. Naumenko, W. J. Quaddakkers, G. Strehl, and G. Borchardt., in Lifetime Modelling of High Temperature Corrosion Processes, eds. M. Schütze, W. J. Quadakkers and J. R. Nicholls, Vol. 34, (Maney Publishing, London, 2001), pp. 83–106.
J. L. Smialek, Acta Materialia 51, 469–483 (2003).
D. Poquillon and D. Monceau, Oxidation of Metals 59, 409–431 (2003).
S. Dryepondt and B. A. Pint, NACE Paper C2013-0002646, presented at NACE Corrosion 2013, (Orlando, FL, 2013).
F. H. Stott, F. A. Golightly and G. C. Wood, Corrosion Science 19, 889–906 (1979).
S. Dryepondt, A. Rouaix-Vande Put and B. A. Pint, Oxidation of Metals 79, 627–638 (2013).
B. A. Pint, P. F. Tortorelli and I. G. Wright, Oxidation of Metals 58, 73–101 (2002).
H. Cama, T.A. Hughes, Proceeding of the 10th Conference on Materials for Advanced Power Engineering, eds. D. Coutsouradis et al., Vol. 1553 (Kluwer Academic Publishers, Liege, October 1994).
C. Capdevila, U. Miller, H. Jelenak and H. K. D. H. Bhadeshia, Materials Science and Engineering A 316, 161–165 (2000).
B. A. Pint, Journal of American Ceramic Society 86, 686–695 (2003).
B. Jonsson, R. Berglund, J. Magnusson, P. Henning and M. Hattestrand, Materials Science Forum 461–464, 455–462 (2004).
S. Dryepondt and B. A. Pint, Materials Science and Engineering 497, 224–230 (2008).
C. S. Tedmon, Journal of the electrochemical society 113, 766–768 (1966).
K. A. Terrani, B. A. Pint, C. M. Parish, C. M. Silva, L. L. Snead and Y. Katoh, Journal of the American Ceramic Society 97, 2331–2352 (2014).
B. A. Pint, L. R. Walker and I. G. Wright, Materials at High Temperatures 26, 211–216 (2009).
B. A. Pint, S. Dryepondt and A. Rouaix-Vande, Put and Y. Zhang, JOM 64, 1454–1460 (2012).
E. Wessel, V. Kochubey, D. Naumenko, L. Niewolak, L. Singheiser and W. J. Quadakkers, Scripta Materialia 51, (10), 987–992 (2004).
D. Naumenko, B. Glesson, E. Wessel, L. Singheiser and W. J. Quadakkers, Metallurgical and Materials Transactions A 38, 2974–2982 (2007).
D. J. Young, D. Naumenko, L. Niewolak, E. Wessel, L. Singheiser and W. J. Quadakkers, Materials and Corrosion 61, 838–844 (2010).
J. L. Smialek, N. S., Jobson, B. Gleeson, D.B. Hovis, and A.H. Heuer, NASA technical report, NASA/TM-2013-217855 34 (2013).
W. M. Pragnell and H. E. Evans, Modeling and Simulation in Material Science and Engineering 14, 733–740 (2006).
I. G. Wright, R. Peraldi and B. A. Pint, Materials Science Forum 461, 579–590 (2004).
G. Merceron, R. Molins and J.-L. Strudel, Materials at High Temperatures 17, 149–157 (2000).
I. G. Wright, B. A. Pint, and Z. P. Lu, Proceedings of the 19th Fossil Energy Materials Annual Conference, (Knoxville, TN, 2005).
W. J. Quadakkers, D. Naumenko, L. Singheiser, H. J. Penkalla, A. K. Tyagi and A. Czyrska-Filemonowicz, Materials and Corrosion 51, 350–357 (2000).
J. L. Smialek and B. K. Tubbs, Metallurgical and Materials Transactions A 26, 427–435 (1995).
J. L. Smialek and B. A. Pint, Materials Science Forum 369–372, 459–466 (2001).
B. A. Pint, Oxidation of. Metals. 45, 1–37 (1996).
D. Naumenko, B. A. Pint and W. J. Quadakkers, Oxidation of Metals 86, 1–43 (2016).
H. E. Evans and M. P. Taylor, Surface and Coatings Technology 94–95, 27–33 (1997).
W. J. Quadakkers, D. Clemens and M. J. Bennett, in Microscopy of Oxidation 3, eds. S. B. Newcomb and J. A. Little, Vol. 1 (Institute of Metals, London, 1997), pp. 195–206.
D. Naumenko, V. Kochubey, L. Niewolak, A. Dymiati, J. Mayer, L. Singheiser and W. J. Quaddakers, Journal of Material. Science 43, 4550–4560 (2008).
V. K. Tolpygo and D. R. Clarke, Surface and Coatings Technology 120, 1–7 (1999).
V. K. Tolpygo and D. R. Clarke, Acta Materialia 13, 3589–3605 (1999).
M. C. Maris-Sida, G. H. Meier and F. S. Pettit, Metallurgical and Materials Transactions A 34, 2609 (2003).
R. Janakiraman, G. H. Meier and F. S. Pettit, Metallurgical and Materials Transactions A 30, 2905 (1999).
Acknowledgements
The authors would like to thanks G. Garner, M Stephens, and T. Lowe for their help with the oxidation testing. They also would like to thank P. Tortorelli and K Terrani for reviewing the manuscript and I. G. Wright who helped guide this research for many years. This research was sponsored by the U.S. Department of Energy, Fossil Energy Crosscutting Research Program.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Dryepondt, S., Turan, J., Leonard, D. et al. Long-Term Oxidation Testing and Lifetime Modeling of Cast and ODS FeCrAl Alloys. Oxid Met 87, 215–248 (2017). https://doi.org/10.1007/s11085-016-9668-2
Received:
Revised:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11085-016-9668-2