CO_(2) High Temperature Corrosion and Its Prevention of Chromia Forming Fe-base Alloys

High temperature corrosion of chromia forming Fe-base alloys by CO_(2) produces not only oxidation but also carburisation.The corrosion kinetics in CO_(2)-rich gas is found to be increased compared with that in air or oxygen.As a result,higher alloy chromium levels are required to achieve protective chromia formation in CO_(2).Corrosion reaction mechanisms in CO_(2) are examined and the internal carburisation of alloys in low carbon activity CO_(2) gases are analysed based on the variation of pO_(2) at the interface of oxide and metal.Carbon penetration through chromia oxide scale has been revealed by atom probe tomography.The strategies to resist CO_(2) corrosion are reviewed by alloying of Si and/or Mn,forming additional diffusion barrier layers,and by adding sulphur to modify oxide grain boundaries to reduce carbon diffusion along the grain boundaries.

INFLUENCES OF SMALL AMOUNTS OF Y AND Ce ON HIGH TEMPERATURE CORROSION PROPERTIES OF M38 ALLOY

High temperature corrosion properties of M38 alloy with and without 0.04 wt-%Y and 0.05 wt-%Ce additions were studied in equilibrated S0_(2)+0_(2)gas mixtures at 850℃and 900℃.It was found that adding Y or Ce decreased the corrosion rate of M38 and changed considerably the surface morphologies and composition of corrosion products on M38.The effectiveness of Y and Ce were also discussed.

Accelerated Corrosion of Pure Fe Induced by Gaseous ZnCl_2 at High Tempreratures

ZnCl2 is one of the dominant aggressive species in waste incinerators or other advanced combustion power generation systems. In this study, the influence of minor amount of gaseous ZnCl2 on the corrosion behavior of pure iron was examined at 600-800℃ in a pure oxygen environment. The corrosion rate usually increased markedly with increasing temperatures at a fixed ZnCl2 content or with increased ZnCl2 contents at a constant temperature. The corrosion products were composed of a thin outer layer of ZnFe2O4 spinel and an inner zone with a much thicker layer of Fe2O3, which exhibited a serious separation from the matrix. Moreover, a molten FeCl2 layer was observed at the scale substrate interface. The accelerated corrosion of pure iron was attributed to the existence of FeCl2 with low melting point on the metal surface, which destroyed the cohesion and adhesion of the oxide scale. The results are discussed in relation to the thermodynamic factors and the presence of volatile compounds in the reaction system.

Uniform corrosion behavior of FeCrAl alloys in borated and lithiated high temperature water

The uniform corrosion behavior of model FeCrAl alloys as well as commercial Zircaloy-4 as reference material were investigated in 360℃borated and lithiated water.The results reveal that FeCrAl alloys exhibited better corrosion resistance than Zircaloy-4.It is found that the oxide films formed on the FeCrAl alloys are composed of outer Fe_(3)O_(4)layer,inner layer consisting of compact spinel layer and porous spinel layer,and transition layer containing Al-Cr-rich oxides and matrix enriched with Fe°.The spinel oxides in the inner layer are FeFe_(2-x-y-z)Cr_(x)Al_(y)MozO_(4).The corrosion mechanism of FeCrAl alloys in high temperature water is discussed.

Effect of temperature on corrosion behavior of alloy 690 in high temperature hydrogenated water

The influence of temperature on the corrosion behavior of Alloy 690 is evaluated using potentiodynamic polarization curves, electrochemical impedance spectra （EIS）, scanning electron microscopy （SEM）, X- ray photoelectron spectroscopy （XPS） and transmission electron microscopy （TEM）. The corrosion rate of Alloy 690 reaches a local maximum at 250℃. The kinetic control step of the growth of oxide film changes from the diffusion process of aqueous-phase ions to the growth of Cr-rich barrier layer in the temperature range of 200-300 ℃. A modified double-layer model is proposed to describe the effect of temperature on the structure and composition of the oxide film.

Role of welding residual strain and ductility dip cracking on corrosion fatigue behavior of Alloy 52/52M dissimilar metal weld in borated and lithiated high-temperature water

Corrosion fatigue behavior of Alloy 52/52 M dissimilar metal weld(DMW)was investigated in borated and lithiated high-temperature water.The fatigue life of Alloy 52/52 M DMW in high-temperature water decreased in comparison with that in air.The fatigue cracks initiated at Alloy 52 M butt weld or at the interface of Alloy 52 buttering and Alloy 52 M butt weld.The welding residual strain and ductility dip cracking in Alloy 52 M butt weld promoted the initiation and propagation of fatigue cracks.The environmentally assisted fatigue damage in high-temperature water is discussed by taking account of microstructure defects.

Proton irradiation assisted localized corrosion and stress corrosion cracking in 304 nuclear grade stainless steel in simulated primary PWR water

Localized deformation and corrosion in irradiated 304 nuclear grade stainless steel in simulated primary water were investigated.The investigation was conducted by comparing the deformation structure,the oxide scale formed at the deformation structure,and their correlation with cracking.The results revealed that increasing the irradiation dose promoted localized corrosion at the slip step and grain boundary,which was primarily attributed to the strain concentration induced by enhanced localized deformation and depletion of Cr at grain boundary.Further,a synergic effect of the enhanced localized deformation and localized corrosion at the slip step and grain boundary caused a higher cracking susceptibility of the irradiated steel.

Effects of cutting parameter on microstructure and corrosion behavior of 304 stainless steel in simulated primary water

The influence of surface conditions on the corrosion behavior of engineering structures has been paid more attention.However,there is still a lack of systematic research on the effect of cutting parameters on material’s microstructure and performance in service.In this paper,the effect of cutting parameters on microstructure and corrosion behaviors of 304 stainless steel in simulated primary water is well investigated.The results show that different cutting parameters can cause the superficial layer a gradient microstructure with nanocrystalized layer on top and deformation band structures underneath.With the similar surface roughness,the deformation microstructure can be very different due to the different cutting parameters.The effect degree on the depth of deformation zone is feed rate>cutting depth>cutting speed.The larger feed rate,lower cutting depth,lower cutting rate may induce a deeper deformation zone.With the increasing depth away from the machined surface,the localized corrosion rate is decreased,and at the same depth the localized corrosion rate along the deformation bands is higher than that along the grain boundaries(GBs).The nanocrystalized surface has a smallest general corrosion rate due to the quick formation of Cr rich oxide film.However,once the corrosion penetrates through this nanocrystalized layer,subsequent preferential corrosion at deformation bands and GBs will dominate and may lead to the significant increase of corrosion rate of the component in high temperature pressurized water.

Corrosion behavior of Ti60 alloy under continuous NaCl solution spraying at 600℃

The corrosion behavior of Ti60 alloy was investigated under continuous NaCl solution spraying at 600℃.Results indicate that the corrosion rate of the Ti60 alloy is lower than that obtained with the solid NaCl deposit film in HO+O.The outer corrosion products are compact layers mainly containing NaTiOand nanocrystalline TiO.The inner layer is mainly composed of TiO,Ti O and SnO.TiO has a lamellar structure,and TiO has a strip-shaped structure.A mixed corrosion mechanism including classic oxidation and active oxidation occurred under NaCl solution spraying environment:the first stage was controlled by the classic oxidation mechanism with the promotion by the active oxidation following parabolic curves,and the second stage was controlled by the active oxidation mechanism following a linear rise in the mass gain curve.The mixed corrosion mechanism between classic oxidation and active oxidation produced a relatively dense Ti oxides scale,which decreased the corrosion rate.

Effects of surface grinding for scratched alloy 690TT tube in PWR nuclear power plant:Microstructure and stress corrosion cracking

Alloy 690TT tube samples with different scratch depths were repaired by grinding treatments using abra-sive papers of two different particle sizes.The microstructure and stress corrosion cracking(SCC)behavior were studied in detail.During grinding,the plastic accumulation zone vulnerable to SCC was removed.Meanwhile,some residual slip steps remained in the scratched area.Corrosion tests lasting 1000,2000,3000,and 4000 h show that the sensitivity and risk of SCC in the scratched area are decreased by grind-ing.Treatment using abrasive particles of a smaller size is more effective.Nevertheless,deep scratches remained hazardous even after the grinding.

Evaluation of Ni-Fe base alloys as inert anode for low-temperature aluminium electrolysis

Isothermal oxidation behaviors of Ni–Fe(wt.%)and of the same alloy with additions of 10 and 15%Cr alloys in the air at 800℃and 900℃and their anodic behaviors in aluminum electrolysis system at 800℃were evaluated.The composition morphologies of oxide scales were characterized by XRD,SEM,and EDS.Results show that the scales formed on Ni–Fe alloy at both temperatures consisted of an inner(Ni,Fe)Olayer and an outer FeOlayer.For Ni–Fe–10Cr alloy,an external(Ni,Fe)O/FeOlayers and an internal oxidation zone were formed at 800°C,while a continuous CrOlayer forms at the internal oxidation zone/substrate interface at 900°C.A multilayer structure oxide of CrO/(Ni,Fe,Cr)O/(Ni,Fe)O/FeOwas formed on Ni–Fe–15Cr alloy at 800°C,while at 900℃the FeObecomes discontinuous disperses in the(Ni,Fe)Olayer close to the surface.Increases in oxidation temperature or Cr content for Ni–Fe–Cr alloys promote the growth of the inner CrOlayer and simultaneously reduce FeOcontent.After 4 h of electrolysis at an anode current density of 0.25 A cm,the oxidation resistance of Ni–Fe–15Cr anode is superior to the Ni–Fe anode.

Repassivation behavior of alloy 690TT in simulated primary water at different temperatures

The repassivation behavior of Alloy 690 T T in simulated primary water at different temperatures was investigated by the rapid scratching electrode technique together with electrochemical measurements.The results showed that the repassivation process had three stages: the initial stage conformed to the place exchange model, the final stage conformed to the high field ion conduction model and in between there was a transition stage. At the initial stage, when the repassivation process of alloys was controlled by the place exchange model, anodic dissolution of substrate was dominated;after the film coverage rate was more than 0.99, the repassivation process of alloys was controlled by high field ion conduction model. Increasing the temperature resulted in a reduction of the repassivation rate and protectiveness of the passive film. The correlations among several mechanisms describing the repassivation behavior of alloys were discussed.

Enamel coating for protection of the 316 stainless steel against tribo-corrosion in molten zinc alloy at 460℃

Hot-dip galvanizing provides excellent corrosion and wear resistance for steels.However,the equipment itself,such as the steel roller,immerged in corrosive molten zinc suffers serious material loss during steel's production.Its protection has become the main technique problem in modern galvanizing line.In this study,an enamel coating was designed and prepared.Its tribo-corrosion in molten zinc alloy(Zn-0.2 wt%Al)at 460℃was investigated in comparison with the traditional WC-12 Co composite coating and the 316 stainless steel.Results indicate that the steel suffers serious material damage.Various corrosion products of Fe_(2) Al_(5) Znx form at the worn surface and the wear scar has reached 200μm deep after merely 5 h tribo-corrosion.Though the two coatings provide an improved tribo-corrosion resistance,for the WC-12 Co coating,its chemical reaction with the molten zinc increases brittleness and promotes cracking.The synergistic wear and corrosion cause its degradation.The enamel coating performs better during tribo-corrosion.It is chemically stable in molten zinc thus able to provide high corrosion resistance.In addition,the amorphous[Si04]network and the self-lubricating CaF_(2) crystallite help it to build up an intact amorphous glaze layer readily at surface on sliding,leading to a reduced wear loss.During the whole tribo-corrosion process,the enamel coating is completely free of cracking,and the Zn penetration is inhibited.

Ni/AlN Composite Coating for Corrosion and Elements Interdiffusion Resistance in Molten Fluoride Salts System

The Ni/AlN composite coating was prepared for increasing corrosion and elements interdiffusion resistance of GH3535 alloy in molten fluoride salts,and the effect of mechanical interlocking on adhesion strength between AlN layer and nickel coating was also studied.Results indicated that the adhesion strength between AlN layer and nickel coating could be significantly enhanced through mechanical interlocking effect,which effectively prevented the nickel coating from flaking off at elevated temperature.Through an etching pre-treatment of AlN layer,the corrosion resistance of the Ni/AlN coated GH3535 alloy in molten FLiNaK salt was further improved,and elements interdiffusion between the substrate and nickel coating was completely suppressed.AlN layer as a diffusion barrier remained compact and continuous in Ni/GH3535 system after high-temperature molten salt corrosion.Moreover,a Ni-P layer consisting of Ni3P and Ni phases formed in the Ni coating after corrosion.

In-situ sampling investigation of deposition and corrosion of convective heating surfaces in a grate type municipal solid waste incineration plant:a case study

Metal corrosion and ash deposition are two common issues in municipal solid waste incineration(MSWI)plants.An in-situ sampling investigation was conducted in an MSWI plant in Jiangsu,China.The deposit samples were collected from 6 convective heating surfaces including the reheaters,superheaters,and economizer.The corrosion samples were obtained from a ruptured tube cut from the tertiary superheater.The element composition,crystal phases,and morphology of deposit and corrosion samples were characterized and analyzed.The results show that S contents of these deposits are 32-45 wt%,considerable Cl(10.63 wt%)was only detected in the deposits of the tertiary superheater.The composition of the deposits varies with the location because the flue gas temperature determines the thermodynamic trend of the sulfation reactions of different chlorides and the SO_(2)equilibrium partial pressure required in these reactions.Ca sulfates mainly exist in deposits at high temperatures(above approximately 500℃).Whereas alkali metal sulfates are the main component of deposits at low temperatures(below approximately 500℃).A multi-layer structure is exhibited on the cross-section of the corrosion samples.The discovery of Cl in the interface between the matrix and the oxide layer confirms that Cl can penetrate the outer oxide film.Besides,polysulfate components were observed inside the metal oxide layers,which indicates that a melt has occurred there.This study has provided a better understanding of ash deposition and corrosion phenomena in MSWI systems and more emphasis should be placed on the research of ash deposition and corrosion mechanisms.

Crack Initiation Mechanism of Z3CN20.09M Duplex Stainless Steel during Corrosion Fatigue in Water and Air at 290 °C

The crack initiation mechanism of a Z3CN20.09M duplex stainless steel （DSS） during corrosion fatigue （CF） in water and air at 290 ℃ was investigated by using a CF cracking machine and a scanning electron microscopy （SEM）. The cracks were initiated successively at the persistent stip bands （PSBs）, phase boundaries （PBs） and pitting corrosion points （PCPs） of the specimens when they were tested in water at 290 ℃, while in airat 290 ℃ the cracks were only initiated at the PSBs and PBs. And the cracks were found mainly to initiate at the PSBs and PBs when the specimens were tested in water and air at 290 ℃, respectively. The results also reveal that the cracks were likely to be initiated at the first 20% of fatigue life of the specimens tested in water at 290 ℃. However, the cracks were not found until 50% of fatigue life when tested in air at 290 ℃. Moreover, the crack numbers of the specimens tested in water at 290 ℃ were much more than those tested in air at 290 ℃.

Effect of TiN diffusion barrier on elements interdiffusion behavior of Ni/GH3535 system in LiF-NaF-KF molten salt at 700℃

A TiN interlayer with high electrical conductivity was prepared between the GH3535 alloy and the Ni coating as a diffusion barrier to elements interdiffusion with the goal of increasing the corrosion resistance of GH3535 alloy in molten FLiNaK salt at 700℃.Results indicated that Ni coating could be directly electroplated on the TiN coated GH3535 alloy without extra conductive transition layer.TiN layer showed excellent thermal and chemical stabilities at elevated temperature in this molten salt system,without phase decomposition.The Ni/TiN composite coating was stable enough to resist corrosion in LiF-NaF-KF molten salt at 700℃.Elements interdiffusion between the substrate and Ni coating could be effectively inhibited and the corrosion resistance of the alloy was greatly enhanced.Besides,the TiN interlayer remained continuous and well adhered to the Ni coating as well as the substrate after corrosion test.

Mechanical Property, Oxidation and Ablation Resistance of C/C–ZrB_2–ZrC–SiC Composite Fabricated by Polymer Infiltration and Pyrolysis with Preform of C_f/ZrB_2

CJC-ZrB2-ZrC-SiC composites were fabricated by polymer infiltration and pyrolysis （PIP） with a preform of G/ZrB2. The carbon fibers and the resin carbon were coated with ceramic layer after PIP in the com- posites. The composite presents a pseudo-plastic fracture due to deflection of cracks and pullout of fibers. The composite has a higher bending strength by this method in comparison with the conventional PIP process due to fewer heat treatment cycles. The static oxidation test shows that the mass loss of the composites is no more than 1% after 20 rain oxidation at 1100 ~C. The ＂core-shell＂ structure between ZrC-SiC ceramic and other phases plays a positive role in preventing the inward diffusion of oxygen. The ablation resistance of the C/C-ZrB2-ZrC-SiC composite samples was tested using a plasma generator. After ablation for 120 s, the mass and linear ablation rates of the composites are 4.65 mg cm-2 s-1 and 2.46 μm s-1, respectively. The short carbon layer shows a better ablation resistance than the nonwoven carbon fabric layer after the ceramic coating is peeled off because of its higher ceramic content.

Characteristics of Oxidation and Oxygen Penetration of Alloy 690 in 600°C Aerated Supercritical Water

The oxide films formed on Alloy 690 exposed to 600 ℃ supercritical water were characterized using mass measurement, X-ray diffraction. Raman spectroscopy, scanning electron microscopy equipped with energy dispersive X-ray spectroscopy and X-ray photoelectron spectroscopy. It was found that the mass gain of the alloy in supercritical water decreased with increasing exposure time. The oxide films have a double-layer structure, with an inner layer rich in Cr and outer layer rich in Ni and Fe after short time and long time exposure. The penetration of the oxide along the grain boundaries was observed, and the penetration depth increased with increasing exposure time. The grain boundaries and voids are the short-path of oxygen diffusion into the metal.