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 1 Carlton House Terrace, London SWlY 5DB Maney Publishing is the trading name of W. S. Maney & Son Ltd 02 001 The Institute of Materials All rights reserved ISBN 1-902653-47-5 The European Federation of Corrosion, W. S. Maney and The Institute of Materials are not responsible for any views expressed in this publication Typesetting by spiresdesign 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