Effects of Fe and Si Additions on Erosion-Oxidation Behavior of Nickel Alloys in Chlorine-Containing Oxidative Atmospheres

Journal of Advanced Materials and Processing

دوره 10، شماره 4، بهمن 2022، صفحه 13-24   

نوع مقاله: Research Paper

نویسندگان

Mohammad Emami^{* 1}؛ Shigenari Hayashi²

¹Assistant Professor, Department of Materials Science and Engineering, University of Bonab, Bonab, Iran.

²Professor, Division of Materials Science and Engineering, Hokkaido University, Sapporo, Japan

چکیده

High-temperature erosion-oxidation (E-O) of Ni-20Cr-(0-30)Fe-(0-4)Si was investigated in fluidized bed waste incineration conditions. The specimens were tested in a rig for 250 h, under the collision of hot silica sand contaminated with 0.5 wt.% of NaCl-KCl salt mixture at a temperature of 700 °C. To have a better understanding of the materials’ behavior, the specimens were also oxidized at 560 °C for 100 h in the atmosphere of air + chlorine vapors. The thickness reduction and mass gain of the specimens were used to evaluate the materials under E-O and oxidation conditions, respectively. The specimens were studied using FESEM, EDS, and XRD analysis. At E-O conditions, Ni-20Cr showed the highest material loss (~17.6 mm). The addition of 30 wt.% of Fe to the alloy decreased the wastage to about 6.7 mm. The E-O resistance of Ni-20Cr-30Fe-4Si was about two times lower than the Si-free alloy which indicates that Si had a detrimental effect on the E-O resistance of the alloys. Under oxidation conditions, Ni-20Cr-30Fe showed the highest resistance with a mass gain of about 0.1 mg/cm². The addition of 4 wt.% Si caused a dramatic decrease in the oxidation resistance of the alloy (mass gain of ~3.8 mg/cm²). The addition of Fe stimulated Cr₂O₃ scale formation by which the higher E-O and oxidation resistance of the alloy were confirmed. In Ni-20Cr, the formation of a multi-component scale, and in Ni-20Cr-30Fe-4Si, a porous surface scale formed through active oxidation were possibly responsible for the poor performance of these alloys.

کلیدواژه‌ها

High temperature erosion-oxidation؛ fluidized bed؛ nickel alloy؛ Fe effect؛ Si effect

مراجع

[1] D.J. Young, High temperature oxidation and corrosion of metals, 2 ed., Elsevier, 2015,

[2] A. Zahs, M. Spiegel, H.J. Grabke, "Chloridation and oxidation of iron, chromium, nickel and their alloys in chloridizing and oxidizing atmospheres at 400–700 °C", Corros. Sci., Vol. 42, No. 6, 2000, pp. 1093-1122.

[3] P. Hou, Y. Niu, T. Sum, J. Stringer, "Effect of HCl on the corrosion and wear of in-bed tubes in a laboratory simulated bubbling fluidized bed", Wear, Vol. 233, No.  1999, pp. 635-646.

[4] M. Noguchi, H. Yakuwa, M. Miyasaka, H. Sakamoto, S. Kosugi, T. Narita, "High temperature erosion-corrosion behavior of boiler tube materials in fluidized-bed waste incinerator conditions", Proc. Proceedings of High Temperature Corrosion and Protection 2000, pp. 573-578.

[5] S. Yoneda, S. Hayashi, Y. Miyakoshi, T. Kogin, E. Ishikawa, M. Noguchi, "Erosion-corrosion behavior of Ni-20Cr-4Fe and ni-20Cr-4Fe-7Mo under fluidized-bed biomass boiler conditions", Corros. Sci., Vol. 205, No.  2022, pp. 110472.

[6] R. Norling, I. Olefjord, "Erosion–corrosion of Fe-and Ni-based alloys at 550° C", Wear, Vol. 254, No. 1-2, 2003, pp. 173-184.

[7] C. Kang, F. Pettit, N. Birks, "Mechanisms in the simultaneous erosion-oxidation attack of nickel and cobalt at high temperature", Metallurgical Transactions A, Vol. 18, No. 10, 1987, pp. 1785-1803.

[8] S. Chang, F. Pettit, N. Birks, "Interaction between erosion and high-temperature corrosion of metals: The erosion-affected oxidation regime", Oxid. Met., Vol. 34, No. 1, 1990, pp. 23-45.

[9] R. Wellman, J. Nicholls, "High temperature erosion–oxidation mechanisms, maps and models", Wear, Vol. 256, No. 9-10, 2004, pp. 907-917.

[10] W. Wu, B. Wei, G. Li, L. Chen, J. Wang, J. Ma, "Study on ammonia gas high temperature corrosion coupled erosion wear characteristics of circulating fluidized bed boiler", Engineering Failure Analysis, Vol. 132, No.  2022, pp. 105896.

[11] E. Gietzen, S. Karimi, N. Goel, S.A. Shirazi, M. Keller, T. Otanicar, "Experimental investigation of low velocity and high temperature solid particle impact erosion wear", Wear, Vol. 506, No.  2022, pp. 204441.

[12] S.B. Mishra, K. Chandra, S. Prakash, "Erosion–corrosion behaviour of nickel and iron based superalloys in boiler environment", Oxid. Met., Vol. 83, No. 1, 2015, pp. 101-117.

[13] T. Sidhu, S. Prakash, R. Agrawal, R. Bhagat, "Erosion-corrosion behaviour of Ni-based superalloy superni-75 in the real service environment of the boiler", Sadhana, Vol. 34, No. 2, 2009, pp. 299-307.

[14] J. Tylczak, "Erosion–corrosion of iron and nickel alloys at elevated temperature in a combustion gas environment", Wear, Vol. 302, No.  2013, pp. 1633-1641.

[15] G. Y. Lai, High-temperature corrosion and materials applications, ed., ASM International, 2007,

[16] M. Emami, S. Hayashi, "High temperature erosion- oxidation behavior of nickel- based alloys containing Mo in fluidized bed waste incineration", iut-jame, Vol. 39, No. 3, 2020, pp. 41-54. (in Persian)

[17] M. Emami, S. Hayashi, "Effects of silicon on high temperature oxidation and erosion-oxidation behaviors of nickel alloys ", Journal of Corrosion Sciences and Engineering, Vol. 24, No.  2020, pp. 7-19. (in Persian)

[18] J.R. Davis, Alloying: Understanding the basics, ed., ASM international, 2001,

[19] H. Izzuddin, S. Hayashi, S. Yoneda, T. Kogin, E. Ishikawa, M. Noguchi, "Effect of Mo on corrosion behavior of Ni20Cr–xMo alloys in air with NaCl–KCl–CaCl2 vapor at 570° c", Materials and Corrosion, Vol. 71, No. 9, 2020, pp. 1488-1499.

[20] T. Gheno, B. Gleeson, "On the hot corrosion of nickel at 700 C", Oxid. Met., Vol. 84, No. 5, 2015, pp. 567-584.

[21] K. Hay, F. Hicks, D. Holmes, "The transport properties and defect structure of the oxide (Fe, Cr) 2O3 formed on Fe- Cr alloys", Materials and Corrosion, Vol. 21, No. 11, 1970, pp. 917-924.

[22] J. Pettersson, H. Asteman, J.-E. Svensson, L.-G. Johansson, "KCl induced corrosion of a 304-type austenitic stainless steel at 600 C; the role of potassium", Oxid. Met., Vol. 64, No. 1, 2005, pp. 23-41.

[23] E. Sadeghimeresht, L. Reddy, T. Hussain, N. Markocsan, S. Joshi, "Chlorine-induced high temperature corrosion of HVAF-sprayed Ni-based alumina and chromia forming coatings", Corros. Sci., Vol. 132, No.  2018, pp. 170-184.

[24] S. Karlsson, J. Pettersson, L.-G. Johansson, J.-E. Svensson, "Alkali induced high temperature corrosion of stainless steel: The influence of NaCl, KCl and CaCl2", Oxid. Met., Vol. 78, No. 1, 2012, pp. 83-102.

[25] K. Segerdahl, J. Pettersson, J.E. Svensson, L.G. Johansson, "Is KCl (g) corrosive at temperatures above its dew point? Influence of KCl (g) on initial stages of the high temperature corrosion of 11% Cr steel at 600° C", Proc. Materials science forum, 2004, pp. 109-116.

[26] M. Schütze, Protective oxide scales and their breakdown, ed., The Institute of Corrosion and Wiley Series on Corrosion and Protection, Sussex, UK, 1991,

[27] Y. Xie, J. Zhang, D.J. Young, W. Zheng, "Effect of Fe on corrosion of Ni-20cr and Ni-30cr alloys in wet CO2 gas at 650 and 700° C", Corros. Sci., Vol. 154, No.  2019, pp. 129-143.

[28] J. Askill, "Tracer diffusion in the chromium–nickel system", physica status solidi (a), Vol. 8, No. 2, 1971, pp. 587-596.

[29] J.-W. Park, C.J. Altstetter, "The diffusion and solubility of oxygen in solid nickel", Metallurgical Transactions A, Vol. 18, No. 1, 1987, pp. 43-50.

[30] D. Pruthi, M. Anand, R. Agarwala, "Diffusion of chromium in inconel-600", J.Nucl. Mater., Vol. 64, No. 1-2, 1977, pp. 206-210.

[31] R. Bender, M. Schütze, "The role of alloying elements in commercial alloys for corrosion resistance in oxidizing‐chloridizing atmospheres. Part i: Literature evaluation and thermodynamic calculations on phase stabilities", Materials and Corrosion, Vol. 54, No. 8, 2003, pp. 567-586.

[32] B. Li, B. Gleeson, "Effects of silicon on the oxidation behavior of Ni-base chromia-forming alloys", Oxid. Met., Vol. 65, No. 1, 2006, pp. 101-122.

[33] H.P. Nielsen, F. Frandsen, K. Dam-Johansen, L. Baxter, "The implications of chlorine-associated corrosion on the operation of biomass-fired boilers", Progress in energy and combustion science, Vol. 26, No. 3, 2000, pp. 283-298.

[34] J.R. Nicholls, D.J. Hall, P.F. Tortorelli, "Hardness and modulus measurements on oxide scales", Materials at High Temperatures, Vol. 12, No. 2-3, 1994, pp. 141-150.