ISSN:
1573-4889
Keywords:
Fe–Al alloys
;
oxidation
;
sulfidation
;
nodular growth
;
corrosion mechanism
Source:
Springer Online Journal Archives 1860-2000
Topics:
Mechanical Engineering, Materials Science, Production Engineering, Mining and Metallurgy, Traffic Engineering, Precision Mechanics
Notes:
Abstract The mechanisms for nodular corrosion-product development were investigatedin various high-temperature gaseous environments. Fe–Al alloys, with5–20 wt.% Al, were exposed in both oxidizing and sulfidizing[p(S2)=10−4 atm, p(O2)=10−25 atm] atmospheres at 700°Cfor times up to 100 hr. The corrosion kinetics were monitored by theuse of a thermogravimetric balance and the morphological developmentthrough light-optical and scanning-electron microscopies,energy-dispersive spectroscopy, electron-probe microanalysis,and quantitative-image analysis. Under both conditions, theelimination of nodule formation was observed by increasing thealuminum content of the alloy, above 5 and 7.5 wt.% Al for oxidizingand sulfidizing environments, respectively, which promoted the growthand maintenance of a continuous surface scale of alumina. For thosealloys that were observed to develop nodular corrosion products, theirmorphological appearance was similar in nature regardless of thecorroding species. The nodules typically consisted of an outeriron-rich product, either sulfide or oxide, that was randomly dispersedacross an alumina scale. Samples from the oxidizing atmosphere displayeda single growth-rate time constant from the kinetics data, suggesting thatthe nodule growth mechanism was by the simultaneous or codevelopment oftwo different (Fe and Al) oxides from the onset of exposure. Measurementof nodule planar diameter and depth of penetration into the alloyindicated that growth occurred through diffusional processes. Kineticsdata from the development of sulfide nodules in the reducingenvironment revealed a different type of mechanism. Multiplegrowth-rate time constants were found due to the localized mechanicalfailure of an initially formed surface scale. At early times in thesulfidizing atmosphere, a low corrosion rate was recorded as acontinuous-alumina scale afforded protection from excessive productdevelopment. However, with the mechanical failure of the scale, sulfurwas able to attack the underlying substrate through a short-circuitdiffusion mechanism that resulted in rapid weight gains from nonprotective,iron sulfide growth. The sulfide morphologies observed were very complex ascontinued growth of the nodule did not solely depend upon the diffusingspecies through the previously formed corrosion products, but also,continued mechanical failure of the oxide scale. It is suggested that thedifference in development mechanisms between the two environments may liein the relative growth rates of the nonprotective, Fe-base corrosionproducts formed.
Type of Medium:
Electronic Resource
URL:
http://dx.doi.org/10.1023/A:1004658530596
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