Lifetime Modelling of High Temperature Corrosion Processes

458 Pages·2001·25.411 MB·English

by  by Schütze, M., Quadakkers, W.J., Nicholls, J.R.Proceedings of an EFC Workshop 2001 - Edited

European Federation of Corrosion
Publications
NUMBER 34
Lifetime Modelling of
High Temperature
Corrosion Processes
Proceedings of an EFC Workshop 2001
Edited by
M. SCHUTZE,W . J. QUADAKKERS J, R. NICHOLLS
AND
Published for the European Federation of Corrosion
by Maney Publishing on behalfof The Institute of Materials
M A N E Y
publishing
Book Number B772
Published in 2001 by Maney Publishing
on behalf of The Institute of Materials
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ISBN 1-902653-47-5
The European Federation of Corrosion, W. S. Maney and
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Made and printed in Great Britain
Contents
Series Introduction ix
Preface xi
Part 1 -Investigation and Modelling of Specific 1
Degradation Processes
SECTION 1.1 Alumina formers 1
I. Life Extension of Alumina-Forming Alloys - Background, Objectives 3
and Achievements of the BRITE/EURAM Programme LEAFA
I.R . NICHOLALNSD M. I.B ENNETT
2. The Oxidation Lifetime of Commercial FeCrAl(RE) Alloys 15
R. NEWTONM,. J. BENNETTJ,. P.W ILBEJ.R R, . NICHOLLDS., N AUMENKO,
W.J . QUADAKKEHR.S A,L -BADAIRY, G. TATLOCGK., STREHL,
G. BORCHARDAT., K OLB-TELIEBP. SJO, NSSON,A . WESTERLUND,
V.G UTTMANMN,. MAIERAN D P.B EAVEN
3. Prediction of Oxide Spallation from an Alumina-Forming Ferritic Steel 37
H.E . EVANS AND J. R. NICHOLLS
4. Mechanistic Understanding of the Chemical Failure of FeCrA1-(RE) Alloys 50
in Oxidising Environments
H. AL-BADAIRGY. J, . TATLOCKH,. E. EVANS, G. STREHLG, . BORCHARDTR, . NEWTOhr,
M. J. BENNETTJ,. R. NICHOLLDS., N AUMENKANOD W. J. QUADAKKERS
5. Critical Role of Minor Element Constituents on the Lifetime Oxidation 66
Behaviour of FeCrA1-(RE) Alloys
D. NAUMENKWO., J. QUADAKKEVR.S G, UTTMANPN. ,B EAVENH, . AL-BADAIRY,
G. J. TATLOCRK., N EWTONJ., R . NICHOLLGS., S TREHL,G . BORCHARDT,
J. LE COZEB, . JONSSON AND A. WESTERLUND
6. Development of a Life Prediction Model for the Chemical Failure of 83
FeCrAl(RE) Alloys in Oxidising Environments
J. R. NKHOLLRS., NEWTONM, .J . BENNETTH, . E. EL~ANHS,. AL-BADAIRY,
G. J. TATLOCDK,. NAUMENKWO,. J . QUADAKKEGR.S S, TREHLA ND G. BORCHARDT
i Contents
zi
7. The Influence of Sample Geometry on the Oxidation and Chemical 107
Failure of FeCrAl(RE) Alloys
G. STREHLV, .G UTTMANDN,. NAUMENKAO., KOLB-TELIEI'S, G. BORCHARDT,
W.J . QUADAKKEJR. SK,L OWERP, .A . BEAVENA ND J. R. NICHOLLS
8. The Role of Bioxidant Corrodents on the Lifetime Behaviour of 123
FeCrAl(RE) Alloys
A. KOLB-TELIEPS, U.M ILLERH,. AL-BADAIRY, G. J. TATLOCKD,. NAUMENKO,
W.J . QUADAKKEGRS. S, TREHLG,. BORCHARDRT., N EWTONJ., R . NICHOLLS,
M.M AIER AND D.B AXTER
9. The Role of the Production Route on the Early Stage of Oxide Scale 135
Formation on FeCrAl-Alloys
v.
H.H ATTENDORAF. ,K OLB-TELIEPS, TH.S TRUNSKUS,Z APOROJCHENKO
AND F. FAUPEL
10. Modelling Internal Corrosion Processes as a Consequence of Oxide 148
Scale Failure
U. KRUPP,S .Y.C HANGA, . SCHIMKAEND H.-J. CHRIST
SECTION 1.2 Iron oxide and chromia formers 165
11. Effects of Minor Alloying Additions on the Oxidation Behaviour 167
of Chromia-Forming Alloys
B. GLEESOANND M. A. HARPER
12. Significance of Scale Spalling for the Lifetime of Ferritic 9-10%Cr Steels 178
During Oxidation in Water Vapour at Temperatures Between
550 and 650°C
R. J, EHLERSP, .I .EN NIS, I!,. SINGHEISEX, w.I. QUADAKKEARNSD T. LINK
13. Understanding the Breakaway Corrosion of Ferritic Stainless Steels 194
in Water Vapour
s. c.
A. GALERIE, HENRYY, .W OUTEJR.-SP,. PETIT, M. MERMOUX, CHEMARIh'
AND L. ANTONI
14. The Influence of Water Vapour and Silicon on the Long Term Oxidation 206
Behaviour of 9Cr Steels
F. DETTENWANGME.R S, CHORRJ., ELLRICHT, . WEBEaRnd M. SCHUTZE
15. Simulation of High Temperature Slurry-Erosion by an in situ 220
Pulsed Laser Spallation Technique
R. OLTRA, I.c . COLSTON, P.P ASQUET AND P.P SYLLAKI
Con tents uii
SECTION 1.3 Composites and coatings 229
16. Theoretical and Experimental Approach for Long Term Modelling of 23 1
Oxidation and Diffusion Processes in MCrAlY Coatings
P. KRUKOVSKYV, .K OLARIKK, . TADLYAA, . RYBNIKOIV. K, RYUKOV
AND M. JUEZ-LORENZO
17. Development of Type I1 Hot Corrosion in Solid Fuel Fired Gas Turbines 246
s.
N. J. SIMMS,P . J. SMITHA, . ENCINAS-OROPESA, RYDERJ,. R. NZCHOLLS
AND J. E. OAKEY
18. Influence of the Salt Composition on the Hot Corrosion Behaviour of 261
Gas Turbine Materials
B. WASCHBUSCH AND H.P . BOSSMANh'
19. High-Temperature Cyclic Oxidation Behaviour of a Hot-Dip 274
Aluminium-Coated 12%Cr Stabilised Ferritic Stainless Steel
L. ANTONANZD B. BAROUX
20. Void Nucleation and Growth at the (Pd,Ni)AlC oating/Alumina Scale 288
Interface During High Temperature Oxidation and Relation to Oxide
Scale Spallation
D.O QUABAN D D. MONCEAU
21. Investigations on the Lifetime of Alumina-forming Ti-Al-Ag Coatings 297
L. NIEWOLAVK.,S HEMETA, . GZLL, . SINGHEISEAXND W. J. QUADAKKERS
SECTION 1.4 Thermal barrier systems 311
22. Interaction of Corrosion and Fatigue in Thermal Barrier Coatings - 313
An Experimental Approach Towards Lifetime Assessment
c. w.
M. BARTSCH, LEYENS AND A.f iYSSER
23. New Approaches to the Understanding of Failure and Lifetime 324
Prediction of Thermal Barrier Coating Systems
D. RENUSCHH., ECHSLERA ND M. SCHUTZE
uiii Contents
Part 2 - General Lifetime Prediction Approaches 33 7
24. Oxidation Lifetimes: Experimental Results and Modelling 339
1. G. WRIGHBT., A. PINT, L. M.H ALLA ND P.F .T ORTORELLI
25. COSIM - A Finite-Difference Computer Model to Predict Ternary 359
Concentration Profiles Associated With Oxidation and Interdiffusion
of Overlay-Coated Substrates
J. A. NESBZTT
26. Corrosion and Lifetime Modelling of Components in Coal Fired 379
Combined Cycle Power Systems
N. J. SIMMSJ,. R. NICHOLALNSD J. E. OAKEY
27. The ASSET Project - A Corrosion Engineering Information System for 398
Metals in Hot Corrosive Gases
R. C. JOHN, A. D. PELTONA, . L. YOUNGW, . T. THOMPSOANND I. G. WRIGHT
28. The NiO/Ni(lll) System in Creep at 550°C: Lifetime Prediction 431
using Several Techniques
L. GAILLEGT., MOULIMN., V IENNAONTD P.B ERGER
List of Abbreviations 439
Index 441
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,
coatings, automotive engineering and cathodic protection. Working Parties on other
topics are established as required.
The Working Parties function invarious ways, e.g.b y 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 Maney Publishing on behalf of The Institute
of Materials.
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
Federation Europeene de la Corrosion, Societe 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
Resistance to environmental corrosion is a major property required for
components which have to operate at high temperatures, e.g. in steam power
plants, chemical and petrochemical plants, waste incineration plants, engines
and gas turbines. The resistance of the materials to high temperature corrosion
relies on the formation of protective surface scales which prevent direct access
of the corrosive environment to the free surface of the material. Extensive
research efforts in recent years have led to the development of a large number of
materials which possess suitable resistance to corrosion in specific applications.
It is important to note that innearly all applications resistance to environmental
corrosion at high temperatures does not mean that the material is ‘immune’
against the aggressive environment. High Temperature Corrosion resistance is
a non-specific definition which in fact means that the rates of corrosion are
reduced to such an extent that the lifetime of the component is sufficient to allow
a safe and economically feasible plant design and operation. This philosophy
implies that the development of models which allow long term extrapolation of
materials degradation by high temperature corrosion and prediction of component
life are of crucial importance for reliable plant operation especially in cases
where materials are subjected to severe service conditions in respect to
temperature, stress and/or corrosivity of the environment.
A two-day workshop held at DECHEMA in Frankfurt/Main on 22 and 23
February 2001 addressed these important aspects of high temperature materials
application. It was organised by the working party ”Corrosion by Hot Gases and
Combustion Products” of the European Federation of Corrosion and followed
the tradition of EFC workshops in various areas of high temperature corrosion
which have been held since the beginning of the 1980s.T he aim of the workshop
was to present the state of the art in the development of lifetime modelling of
high temperature oxidation and corrosion processes and the incorporation of
these models in component design.
The present volume contains the written contributions to this workshop. In
their papers the authors report results from recent research projects and thus
provide a comprehensive survey of the present knowledge and understanding
of this technologically important topic. The first eight papers came out of a joint
European project with the acronym LEAFA which was especially devoted to the
lifetime extension of alumina-forming alloys. These eight papers at the same
time represent the final report of this project. The other papers come from
Preface xii
various projects in Europe and the USA. The contribution of each author to this
monograph is gratefully acknowledged and recognised in the authorship of
individual papers: thanks are also due to all colleagues who helped by carefully
refereeing the papers.
M. SCHUTZE Karl-Winnacker-Institut der DECHEM.A e.V., Frankfurt, Germany
Chairman of EFC Working Party "Corrosion by Hot Gases and Combustion
Products"
W. J. QUADAKKERFSo rsckungszentrum Jiilick, Institute for Materials and Processes in Energy
Systems, Jiilich, Germany
J. R. NICHOLLS Cranfield University, United Kingdom
Previous EFC publications from the WP on 'Corrosion by Hot Gases
and Combustion Products':
EFC No. 14 Guidelines for Methods of Testing and Research in
High Temperature Corrosion
EFC No. 27 Cyclic Oxidation of High Temperature Materials