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The behaviour of commercial FeCrAlRE alloys in nitrogen-oxygen – water vapour bioxidant environments

Abstract The corrosion behaviour of a range of commercial FeCrAlRE alloys (MA956, ODM751, PM2000, Kanthal AF, Kanthal APM and Aluchrom YHf) have been examined in nitrogen–oxygen-H2O or N2–H2–H2O bioxidant environments, at temperatures between 1100°C and 1350°C. The corrosion behaviour is governed by the competition between oxidation leading to protective alumina formation/ maintenance and nitrogen ingress leading to nitridation of the matrix alloy. Key issues addressed by four series of experiments, have included: the influence of a pre-formed protective alumina scale; the oxidant level required to form/reheal a protective oxide scale; the role of mechanical failure of the scale above the critical thickness for cracking/spallation in oxygen rich environments; chemical failure of the protective oxide scale leading to breakaway (non-protective) attack and in particular, the potential roles in such failure processes of nitridation concurrent with, and following defective oxide scale formation, and of oxidation following nitridation. Detailed characterisation of the chemical composition and physical microstructure of the attack of the respective alloys was undertaken using a range of surface analytical techniques, including X-ray diffraction, optical and scanning electron microscopy and energy dispersive X-ray analysis.