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Invited Review Paper in Commemoration of Over 50 Years of Oxidation of Metals: Addressing the Role of Water Vapor on Long-Term Stainless Steel Oxidation Behavior

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Abstract

In the past 20 years, it has become clear that the long-term exposure of chromia-forming austenitic stainless steels to air containing ~ 10 vol% water vapor at 650–800 °C significantly increases the Cr consumption rate compared to laboratory air. However, a similar acceleration does not occur in 100% steam because O2 is not available to form volatile CrO2(OH)2. This accelerated Cr loss is particularly important for thin-walled components like gas turbine recuperators. Typically, conventional austenitic stainless steels exhibit accelerated attack (i.e., rapid formation of Fe-rich oxide nodules), while higher alloyed steels resist this type of degradation until the alloy surface becomes Cr depleted. The development of strategies and solutions for this issue are reviewed. Model Fe–Cr–Ni alloys have been used to study composition effects on this behavior. For example, increasing the Mn content up to ~ 4 wt% was not beneficial, but increasing the Ni content improved oxidation resistance in this environment. However, at 650–700 °C even highly alloyed steels showed surface Cr depletion at alloy grain boundaries resulting in Fe-rich oxide nodule formation. The path forward for this issue will require more refined mechanistic understanding and increased used of modeling to develop better application-specific lifetime models to identify the most cost-effective alloy solutions.

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Acknowledgements

I would like to thank J. D. Vought, L. D. Chitwood, J. Moser, K. Reeves, T. Lowe, G. Garner and H. Longmire at ORNL for assistance with the experimental work and many conversations with I. G. Wright, P. F. Tortorelli and P. J. Maziasz on this subject. S. Dryepondt, M. Romedenne, R. Pillai and P. F. Tortorelli provided many helpful comments on the manuscript. Special thanks are due to Solar Turbines (P. Montague, M. Fitzpatrick, R. Klug), Capstone Turbine Corporation (W. Matthews, D. Vicario) and ATI Allegheny Ludlum (J. Rakowski) for providing commercial foil for testing as well as J. Nash, J. Kesseli and J. Armstrong (formerly Ingersoll Rand); all of these industrial collaborators generously provided many beneficial interactions over the past 25 years, beginning when I was serendipitously introduced to this problem at a meeting that none of my more senior co-workers could attend. This research has been strongly supported by U.S. Department of Energy (DOE), Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office, Combined Heat and Power Program and previously under the DOE Distributed Energy Program and initially under a cooperative research agreement with Solar Turbines, Inc.

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  1. Corrosion Science and Technology Group, Materials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN, 37831-6156, USA

    Bruce A. Pint

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Pint, B.A. Invited Review Paper in Commemoration of Over 50 Years of Oxidation of Metals: Addressing the Role of Water Vapor on Long-Term Stainless Steel Oxidation Behavior. Oxid Met 95, 335–357 (2021). https://doi.org/10.1007/s11085-020-10012-9

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