Developments in High Temperature Corrosion and Protection of Materials

High temperature corrosion is a phenomenon that occurs in components that operate at very high temperatures, such as gas turbines, jet engines and industrial plants. Engineers are constantly striving to understand and prevent this type of corrosion. This book examines the latest developments in the understanding of high temperature corrosion processes and protective oxide scales and coatings.

Part one looks at high temperature corrosion. Chapters cover diffusion and solid state reactions, external and internal oxidation of alloys, metal dusting corrosion, tribological degradation, hot corrosion, and oxide scales on hot-rolled steel strips. Modern techniques for analysing high temperature oxidation and corrosion are also discussed. Part two discusses methods of protection using ceramics, composites, protective oxide scales and coatings. Chapters focus on layered ternary ceramics, alumina scales, Ti-Al intermetallic compounds, metal matrix composites, chemical vapour deposited silicon carbide, nanocrystalline coatings and thermal barrier coatings. Part three provides case studies illustrating some of the challenges of high temperature corrosion to industry and how they can be overcome. Case studies include the petrochemical industry, modern incinerators and oxidation processing of electronic materials.

This book will be a valuable reference tool for engineers who develop heat resistant materials, mechanical engineers who design and maintain high temperature equipment and plant, and research scientists and students who study high temperature corrosion and protection of materials.

ISBN 1 84569 219 5

Introduction
W Gao and Z Li, The University of Auckland, New Zealand

Part 1 Developments In High Temperature Corrosion

Diffusion and solid state reactions
B Pieraggi, ENSIACET, France
 - Introduction
 - Kirkendall effect and interface actions in polyphased systems
 - Application to the role of oxide/metal interface during oxide scale growth
 - Elementary interface reactions, interface structure and interface actions
 - Growth stresses and interfacial processes
 - Conclusions and future trends
 - Acknowledgement
 - References

Transition between external and internal oxidation of alloys
Y He, University of Science and Technology Beijing, China and Z Li and W Gao, The University of Auckland, New Zealand
 - Introduction
 - Thermodynamics of alloy oxidation
 - Model for the transition from external to internal oxidation of alloys
 - Summary
 - Acknowledgements
 - References

Modern analytical techniques in high temperature oxidation and corrosion
M Graham, National Research Council, Canada
 - Introduction
 - Metals and alloys
 - Semiconductors
 - Concluding remarks
 - Acknowledgements
 - References

Metal dusting corrosion of metals and alloys
T A Ramanarayanan, Princeton University, USA and C M Chun, Exxon Mobil, USA
 - Introduction
 - Background
 - Nature of the metal dusting environment
 - Metal dusting of pure metals
 - Metal dusting of alloys
 - Control of metal dusting
 - Future trends
 - Sources of further information and advice
 - References

Tribological degradation at elevated temperatures
M Roy, Defence Metallurgical Research laboratory, India
 - Introduction
 - High temperature wear test facilities
 - Important features of elevated temperature tribological degradation: sliding wear
 - The important features of elevated temperature erosive wear
 - Important features of elevated temperature abrasive wear
 - Recent developments
 - Future trends
 - Concluding remarks
 - Acknowledgement
 - References

Hot corrosion of alloys and coatings
S Prakash, Indian Institute of Technology Roorkee, India
 - What is hot corrosion?
 - Types of hot corrosion
 - Chemistry of hot corrosion
 - Salt fluxing
 - Salt chemistry
 - Hot corrosion of Fe, Ni and Co based alloys
 - How to avoid hot corrosion
 - High temperature coatings
 - References

Oxide scales on hot-rolled steel strips
R Y Chen and W Y D Yuen, BlueScope Steel, Australia
 - Introduction
 - Long term oxidation of iron and steel
 - Short time oxidation of iron and steel
 - Deformation and failure of oxide scale during hot rolling
 - Electron backscatter diffraction (EBSD) analyses of oxide scale structure
 - Conclusions
 - References

Part 2 Developments In Protective Oxide Scales And Coatings

High-temperature corrosion mechanisms in layered ternary ceramics
Z J Lin, M S Li and Y C Zhou, Chinese Academy of Sciences, China
 - Introduction
 - Microstructure and synthesis of layered ternary ceramics (LTCs)
 - High-temperature oxidation mechanism of layered ternary ceramics
 - Hot corrosion mechanism of layered ternary ceramics
 - Summary and future trends
 - Acknowledgement
 - References

Formation and growth of protective alumina scales
S Chevalier, Institut Carnot Bourgogne, France
 - Introduction
 - Alumina scales: growth and properties
 - Influence of minor element addition
 - Recent developments in alumina-forming materials: intermetallics
 - References

Oxidation of Ti-Al intermetallic compounds
S Taniguchi, Osaka University, Japan
 - Introduction
 - Oxidation characteristics of TiAl base alloys
 - Oxidation characteristics of Ti3Al and Ti3Al-Nb alloys
 - Oxidation characteristics of TiAl3 base materials
 - Future trends
 - Acknowledgement
 - References

Oxidation of metal matrix composites
Z Li and W Gao, The University of Auckland, New Zealand
 - Introduction
 - Classification of metal matrix composites
 - Reinforcing phase
 - Matrix
 - Fabrication
 - Mechanical property
 - Corrosion of metal matrix composites
 - Titanium alloys, titanium aluminides and composites
 - Oxidation of titanium matrix composites
 - Oxidation of iron aluminide based composites
 - Oxidation of nickel aluminide based composites
 - Oxidation of niobium silicide-based in situ composites
 - Concluding remarks
 - References

Design strategies for new oxidation-resistant high temperature alloys
B A Pint, Oak Ridge National Laboratory, USA
 - Introduction
 - Chromia-forming alloys
 - Alumina-forming alloys
 - Reactive element (RE) optimisation
 - Strategies for increasing lifetime
 - "Fantasy" high temperature materials
 - Future trends
 - Summary
 - Sources of further information and advice
 - Acknowledgments
 - References

Oxidation behaviour of chemical vapour deposited silicon carbide
T Goto, Tohoku University, Japan
 - Introduction
 - Synthesis of chemical vapor deposition (CVD) silicon carbide (SiC) thick plates
 - Passive oxidation of silicon carbide
 - Active oxidation of silicon carbide
 - Bubble formation of silicon carbide
 - Summary
 - References

Oxidation resistant nanocrystalline coatings
X Peng and F Wang, Chinese Academy of Sciences, China
 - Nanocrystalline materials and coatings
 - Oxidation-resistant coatings
 - Oxidation-resistant nanocrystalline coatings
 - Concluding remarks
 - Acknowledgements
 - References

Thermal barrier coatings
H Xu, H Guo and S Gong, Beijing University of Aeronautics & Astronautics, China
 - Introduction
 - Manufacturing of thermal barrier coatings (TBCs)
 - Thermal barrier coating materials
 - Failure of thermal barrier coatings
 - Future trends
 - References

Part 3 Case Studies

High temperature corrosion problems in the petrochemical industry
Y He and Z Ning, University of Science and Technology Beijing, China and W Gao, The University of Auckland, New Zealand
 - Introduction
 - High temperature sulfidation
 - High temperature naphthenic acid corrosion
 - Case studies in high temperature naphthenic acid corrosion
 - High temperature corrosion of furnace radiant tubes
 - References

Oxidation processing of electronic materials
Z Li and W Gao, The University of Auckland, New Zealand
 - Introduction
 - Oxidation processing in semiconductors
 - Oxidation of precursors for preparation of superconductors
 - Preparation of ZnO films and nanostructures by oxidation
 - Concluding remarks
 - References

Corrosion in modern incinerators
Y Kawahara, Mitsubishi Heavy Industries Ltd., Japan
 - Introduction
 - Recent tends in waste-to-energy plants and materials
 - Corrosion environment of waste-to-energy boilers
 - Progress of high temperature corrosion-resistant materials for superheaters
 - Corrosion mechanisms of materials
 - Progress of corrosion-resistant coatings for waterwall tubes
 - Deterioration mechanisms of spray coatings
 - Corrosion testing and environmental monitoring methods
 - Corrosion lifetime evaluation of materials
 - Summary
 - References