Cyclic Oxidation of High Temperature Materials - Proceedings of an EFC Workshop, Frankfurt/Main, 1999 PDF
Preview Cyclic Oxidation of High Temperature Materials - Proceedings of an EFC Workshop, Frankfurt/Main, 1999
European Federation of Corrosion Publications NUMBER 27 Cyclic Oxidation of High Temperature Materials Mechanisms, testing methods, characterisation and life time estimation Proceedings of an EFC Workshop, FrankfurtlMain, 1999 Edited by M. SCHUTZE& W. 1. QUADAKKERS Published for the European Federation of Corrosion by IOM Communications Book Number 726 Published in 1999 by IOM Communications Ltd 1 Carlton House Terrace, London SWlY 5DB IOM Communications Ltd is a wholly-owned subsidiary of The Institute of Materials 0 1999 IOM Communications Ltd All rights reserved ISBN 1-86125-100-9 Neither the EFC nor The Institute of Materials is responsible for any views expressed in this publication Design and production by SPIRES Design Partnership Made and printed in Great Britain Contents Series Introduction ix Preface xi ... Foreword Xlll Part 1 - Oxidation and Failure Mechanisms Under 1 Cyclic Conditions 1. Interfacial Crack Growth During Temperature Changes 3 H. E. EVANS 2. The Influence of Surface Pre-treatment on the Integrity of 17 Alumina Scales on the ODS Alloy MA 956 V. GUTTMANFN. ,H UKELMANPN.A, . BEAVENA ND G. BORCHARDT 3. The Effect of Water Vapour on the Oxidation of Alloys that Develop 38 Alumina Scales for Protection R. JANAKIRAMAN, G. H. METEARN D F.S . PETTIT 4. The Influence of Thermal Cycling on Internal Oxidation and 63 Nitridation of Nickel-Base Alloys S. Y. CHANGL,I . KRUPPA ND H.-J. CHRIST 5. Cyclic Oxidation of Thin FeCrAl(RE) Foils in Air: SEM and 82 EPMA Investigations G. STREHLH, . AL-BADAIRYL,. M. RODRIGUEJ.Z K,L OWER,G . BORCHARDT, G. TATLOCAKN D A. J, CRIADO 6. Cyclic Oxidation of PM 1000 95 H.-PM.A RTINZF,. E. H. MULLERAN D K. PRANDINI vi Contents Part 2 - Test Procedures and Parameters 209 Influencing Cyclic Oxidation Behaviour 7. Effect of Cycle Frequency on High-Temperature Oxidation 111 Behaviour of Alumina- and Chromia-Forming Alloys B. A. PINT, P.F , TOKTORELLI AND 1. G. WRIGHT 8. The Effect of Thermal Cycling on the Mechanical Failure of 133 Alumina Scales formed on Commercial FeCrA1-RE Alloys J. P.W ILBEMR., J . BENNETTANDJ. R. NICHOLLS 9. Cyclic Oxidation Testing and Modelling: a NASA Lewis Perspective 148 J. L. SMIALEKJ., A. NESBITCT., A. BARRETTA ND C. E. LOWELL 10. Significance of Experimental Procedures on the Hot Corrosion 169 Behaviour of Nickel-Base Alloys under Cyclic Conditions C. LEYENSI,. G. WRIGHBT., A . PINTA ND P.F. TORTORELLI 11. Advantages of Ferritic Stainless Steels in Cyclic High Temperature 187 Conditions L. ANTONANID J, M.H ERBELIN 12. Investigation of a New Methodology in High Temperature Oxidation 198 P.V ANGELI 13. Effect of Implanted Silicon on the Cyclic Oxidation Behaviour of 209 AISI 304 and AISI 430 Stainless Steels F.J . PEREZ, M. I.C RISTdBAL, P.H IERROAN D F.P EDRAZA 14. The Importance of Relevant Experimental Parameters for 225 High Temperature Cyclic Oxidation Experiments - An attempt for a checklist V. A. C. HAANADPEALN,D M.F . STROOSNIJDER 15. Corrosion of Heat Exchanger Steels in Cycled Gas Atmospheres 240 at 600°C M.M AZEARN D J. F.N ORTON 16. Behaviour of Protective Coatings against Sulfidation under Cyclic 259 Conditions T. WEBEARND M.S CHUTZE Contents vii Part 3 - Long Term Behaviour and Near-Service Conditions 2 71 17. Long-Term, Cyclic Oxidation Behaviour of Three 273 Chromia-Forming Alloys Exposed to Air at 982°C M. A. HARPEARN D B. GLEESON 18. Oxidation Limited Life of FeCrAl Based Alloys During 287 Thermal Cycling D. NAUMENKLO. ,S INGHEISEARND W. J. QUADAKKERS 19. Characterisation of Oxidation Resistance of Heat-resistant 307 Cast Alloys in the 5 x 24-h Test W. STEINKUSCH 20. Cyclic Oxidation Testing by Resistance Heating 324 B. JONSSON,A . WESTERLUANNDD G. LANDOR Part 4 - The Behaviour of Coatings Under Cycling Conditions 337 21. Thermal Cycling Testing of Thermal Barrier Coatings 339 R. ANTONS., K. JHA, D. CLEMENWS,. MALLENELR. ,S INGHEISER AND W. J. QUADAKKERS 22. Investigations of the Microstructure and Stress State in Oxide Scales 357 and Buried Layers with Diffraction Methods T. SCHMACKERASN D W. REIMERS 23. Numerically Calculated Oxidation Induced Stresses in Thermal 373 Barrier Coatings on Cylindrical Substrates G. KERKHOFFR.. VAGEANND D.S TOVER 24. Electron Beam-Physical Vapour Deposited Thermal Barrier 383 Coating Lifetime Response to Various Bond Coat Pre-treatments K. FRITSCHERU, . SCHULZA ND M. SCHMUCKEX 25. Degradation of Aluminide, Chromium-Aluminide and Thermal 392 Barrier Coatings in Conditions of Cyclic Thermal and Mechanical Loads L. SWADZBA,B . MENDALAAN D M. HETMA~~CZYK 26. Thermal Cycling of NiAl Intermetallic Coatings Prepared by 408 High Velocity Oxy-Fuel (HVOF) Thermal Spraying 1. A. HEARLEJY. ,A . LITTLE AND A. J. STURGEON ... Contents Vlll 27. Development of Metal-Organic Chemical Vapour Deposition 421 (MOCVD) Coatings for Protection of Alloys under High Temperature Cyclic Conditions S. CHEVALIEGR., BONNETC, . VALOJT. ,C . COLSONAN D J. P. LARPIN 28. Mullite Based Oxidation Protection for Silicon 431 Carbide-Carbodcarbon Composites in Air at Temperatures up to 1900K H. FRITZE,A . SCHNITTKEGR. ,B ORCHARDTT., WmE AND B. SCHULTRICH 29. Cyclic Oxidation - Guidelines for Test Standardisation, Aimed 437 at the Assessment of Service Behaviour 1. R. NICHOLALNSD M. J. BENNETT List of Abbreviations 471 Index 473 European Federation of Corrosion Publications Series Introduction The EFC, incorporated in Belgium, was founded in 1955 with the purpose of promoting European co-operation in the fields of research into corrosion and corrosion prevention. Membership is based upon participation by corrosion societies and committees in technical Working Parties. Member societies appoint delegates to Working Parties, whose membership is expanded by personal corresponding membership. The activities of the Working Parties cover corrosion topics associated with inhibition, education, reinforcement in concrete, microbial effects, hot gases and combustion products, environment sensitive fracture, marine environments, surface science, physico-chemical methods of measurement, the nuclear industry, computer based information systems, the oil and gas industry, the petrochemical industry and coatings. Working Parties on other topics are established as required. The Working Parties function in various ways, e.g. by preparing reports, organising symposia, conducting intensive courses and producing instructional material, including films. The activities of the Working Parties are co-ordinated, through a Science and Technology Advisory Committee, by the Scientific Secretary. The administration of the EFC is handled by three Secretariats: DECHEMA e. V. in Germany, the Societe de Chimie Industrielle in France, and The Institute of Materials in the United Kingdom. These three Secretariats meet at the Board of Administrators of the EFC. There is an annual General Assembly at which delegates from all member societies meet to determine and approve EFC policy. News of EFC activities, forthcoming conferences, courses etc. is published in a range of accredited corrosion and certain other journals throughout Europe. More detailed descriptions of activities are given in a Newsletter prepared by the Scientific Secretary. The output of the EFC takes various forms. Papers on particular topics, for example, reviews or results of experimental work, may be published in scientific and technical journals in one or more countries in Europe. Conference proceedings are often published by the organisation responsible for the conference. In 1987 the, then, Institute of Metals was appointed as the official EFC publisher. Although the arrangement is non-exclusive and other routes for publication are still available, it is expected that the Working Parties of the EFC will use The Institute of Materials for publication of reports, proceedings etc. wherever possible. The name of The Institute of Metals was changed to The Institute of Materials with effect from 1 January 1992. The EFC Series is now published by the wholly-owned subsidiary of The Institute of Materials, IOM Communications Ltd. A. D. Mercer EFC Series Editor, The Institute of Materials, London, UK X Series Introduction EFC Secretariats are located at: Dr B A Rickinson European Federation of Corrosion, The Institute of Materials, 1 Carlton House Terrace, London, SWlY 5DB, UK Mr P Berge FkdQation Europgene de la Corrosion, Soci6t6 de Chimie Industrielle, 28 rue Saint- Dominique, F-75007 Paris, FRANCE Professor Dr G Kreysa Europaische Foderation Korrosion, DECHEMA e. V., Theodor-Heuss-Allee 25, D- 60486, Frankfurt, GERMANY Preface During actual service high temperature materials are frequently subjected to environmental attack and mechanical stresses. The high temperature resistance of these materials relies to a large extent on the formation of a protective oxide scale on their surfaces and on their ability to maintain the protective effect during long term operation. Failure of these protective scales followed by enhanced corrosive attack mostly occurs as a result of externally applied stresses in combination with stresses induced by temperature changes during plant start-up and shut-down. In most laboratory investigations, materials behaviour with respect to protective scale formation is often tested only under isothermal conditions. However, for the assessment of the suitability of high temperature materials in practical applications, the high temperature oxidation behaviour at constant temperature is only of limited importance. The oxidation behaviour under temperature cycling gives a much better indication of what has to be expected when the materials are exposed to service conditions. Therefore, cyclic oxidation has become one of the most frequently used testing procedures because it is a simple laboratory test that simulates the conditions frequently encountered during actual service. The method has widely been applied in many industrial and scientific laboratories, but up to now neither standards nor general recommendations exist which can be used by all investigators. This makes ranking of materials and comparison of results obtained in different laboratories extremely difficult. In recent years refinements of the cyclic oxidation testing method, e.g. by incorporating new techniques, such as acoustic emission or thin layer activation measurements, have taken place. Furthermore, well developed models concerning the failure of protective oxide scales are now available. Taking all this into account, a workshop was organised by the working party 'Corrosion by Hot Gases and Combustion Products' of the EFC which took place at Karl-Winnacker-Institut der DECHEMA e.V. on 25 and 26 February 1999, following the tradition of workshops in various areas of high temperature corrosion held by the EFC working party since the beginning of the 1980s. One of these workshops (whose results are published in EFC Publication No. 14) included a first attempt towards standardisation of various high temperature corrosion testing methods, however cyclic oxidation testing was only one of the various aspects in this publication. The 1999 Workshop was devoted solely to this topic and the aims were to summarise the present state-of-the-art in respect to this type of materials testing, and to discuss possible further steps towards standardisation of the cyclic oxidation testing method as a reliable tool for high temperature materials characterisation. The present volume contains the papers of this Cyclic Oxidation Workshop and is structured according to the various presentation and poster sessions: Oxidation and Failure Mechanisms under Cyclic Conditions Test Procedures and Parameters Influencing the Cyclic Oxidation Behaviour xii Preface Long-Term Behaviour and Near-Service Conditions The Behaviour of Coatings under Cycling Conditions Conclusions on the Present State of Knowledge In their papers the authors report work which has been performed very recently in the field of materials and coating behaviour under cyclic conditions, and thus provide a comprehensive survey of the present knowledge and understanding of this clearly focused, technologically important topic. The contribution of each author is gratefully acknowledged and thanks are also due to the referees of the papers. M. SCHUTZE Karl-Winnacker-Institut der DECHEMA e.V .,F rankfurt, Germany Chairman of EFC Working Party ”Corrosion by Hot Gases and Combustion Products” W. J. QUADAKKERS Forschungzentrum Jiilich, Institute for Materials and Processes in Energy Systems, Jiilich, Germany
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