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Mechanism and Control of Carbon Deposition on High Temperature Alloys

In solid oxide fuel cells, the preferred anode electrode is a cermet of Ni-yttria-stabilized zirconia. When high carbon activity (a c > 1) and low oxygen partial pressure (p O 2 ) environments are encountered in the anode compartment, carbon deposition occurs in concert with a corrosion reaction known as metal dusting. Thus high temperature alloys that could resist the carbon deposition/ metal dusting reaction are needed. The present work has led to a carbon deposition-resistant alloy in which the initial rapid formation of a surface MnO layer blocks carbon transfer. Subsequently, a Mn-rich spinel layer (MnCr 2 O 4 ) develops beneath the MnO layer providing long-term resistance to carbon transfer and corrosion. In the alloy, 20Fe-40Ni-10Mn-30Cr, a layer of MnO forms almost instantaneously when exposed to high carbon activity environments over the temperature range 650-950°C. In the above environment, MnO is an n-type conductor and allows rapid Mn transport via Mn vacancies. Beneath this MnO layer, a diffusion resistant, adherent MnCr 2 O 4 film develops.