Effect of Molybdenum on the Corrosion Behavior of High-Entropy Alloys CoCrFeNi 2

The corrosion behavior of high-entropy alloys (HEAs) CoCrFeNi2 and CoCrFeNi2Mo0.25 was investigated in 3.5 wt. percent sodium chloride (NaCl) at 25°C by electrochemical methods. Their corrosion parameters were compared to those of HASTELLOY® C-276 (UNS N10276) and stainless steel 316L (UNS 31600) to assess the suitability of HEAs for potential industrial applications in NaCl simulating seawater type environments. The corrosion rates were calculated using corrosion current determined from electrochemical experiments for each of the alloys. In addition, potentiodynamic polarization measurements can indicate active, passive, and transpassive behavior of the metal as well as potential susceptibility to pitting corrosion. Cyclic voltammetry (CV) can confirm the alloy susceptibility to pitting corrosion. Electrochemical impedance spectroscopy (EIS) elucidates the corrosion mechanism under studied conditions. The results of the electrochemical experiments and scanning electron microscopy (SEM) analyses of the corroded surfaces revealed general corrosion on alloy CoCrFeNi2Mo0.25 and HASTELLOY C-276 and pitting corrosion on alloy CoCrFeNi2 and stainless steel 316L

Ultra supercritical turbines--steam oxidation

Ultra supercritical (USC) power plants offer the promise of higher efficiencies and lower emissions, which are goals of the U.S. Department of Energy?s Advanced Power Systems Initiatives. Most current coal power plants in the U.S. operate at a maximum steam temperature of 538?C. However, new supercritical plants worldwide are being brought into service with steam temperatures of up to 620?C. Current Advanced Power Systems goals include coal generation at 60% efficiency, which would require steam temperatures of up to 760?C. This research examines the steamside oxidation of advanced alloys for use in USC systems, with emphasis placed on alloys for high- and intermediate-pressure turbine sections. Initial results of this research are presented

Electrochemical noise sensors for detection of localized and general corrosion of natural gas transmission pipelines

The U.S. Department of Energy, National Energy Technology Laboratory funded a Natural Gas Infrastructure Reliability program directed at increasing and enhancing research and development activities in topics such as remote leak detection, pipe inspection, and repair technologies and materials. The Albany Research Center (ARC), U.S. Department of Energy was funded to study the use of electrochemical noise sensors for detection of localized and general corrosion of natural gas transmission pipelines. As part of this, ARC entered into a collaborative effort with the corrosion sensor industry to demonstrate the capabilities of commercially available remote corrosion sensors for use with the Nation's Gas Transmission Pipeline Infrastructure needs. The goal of the research was to develop an emerging corrosion sensor technology into a monitor for the type and degree of corrosion occurring at key locations in gas transmission pipelines

Electrochemical Noise Sensors for Detection of Localized and General Corrosion of Natural Gas Transmission Pipelines. Final Report for the Period July 2001-October 2002

The U.S. Department of Energy, National Energy Technology Laboratory funded a Natural Gas Infrastructure Reliability program directed at increasing and enhancing research and development activities in topics such as remote leak detection, pipe inspection, and repair technologies and materials. The Albany Research Center (ARC), U.S. Department of Energy was funded to study the use of electrochemical noise sensors for detection of localized and general corrosion of natural gas transmission pipelines. As part of this, ARC entered into a collaborative effort with the corrosion sensor industry to demonstrate the capabilities of commercially available remote corrosion sensors for use with the Nation's Gas Transmission Pipeline Infrastructure needs. The goal of the research was to develop an emerging corrosion sensor technology into a monitor for the type and degree of corrosion occurring at key locations in gas transmission pipelines

Corrosion in a temperature gradient

High temperature corrosion limits the operation of equipment used in the Power Generation Industry. Some of the more destructive corrosive attack occurs on the surfaces of heat exchangers, boilers, and turbines where the alloys are subjected to large temperature gradients that cause a high heat flux through the accumulated ash, the corrosion product, and the alloy. Most current and past corrosion research has, however, been conducted under isothermal conditions. Research on the thermal-gradient-affected corrosion of various metals and alloys is currently being studied at the Albany Research Center’s SECERF (Severe Environment Corrosion and Erosion Research Facility) laboratory. The purpose of this research is to verify theoretical models of heat flux effects on corrosion and to quantify the differences between isothermal and thermal gradient corrosion effects. The effect of a temperature gradient and the resulting heat flux on corrosion of alloys with protective oxide scales is being examined by studying point defect diffusion and corrosion rates. Fick’s first law of diffusion was expanded, using irreversible thermodynamics, to include a heat flux term – a Soret effect. Oxide growth rates are being measured for the high temperature corrosion of cobalt at a metal surface temperature of 900ºC. Corrosion rates are also being determined for the high temperature corrosion of carbon steel boiler tubes in a simulated waste combustion environment consisting of O2, CO2, N2, and water vapor. Tests are being conducted both isothermally and in the presence of a temperature gradient to verify the effects of a heat flux and to compare to isothermal oxidation

Intermittent Cathodic Protection for Steel Reinforced Concrete Bridges

Thermal-sprayed zinc anodes are used for impressed current cathodic protection (ICCP) systems on Oregon's reinforced concrete coastal bridges to prevent chloride-induced corrosion damage. Thermal-sprayed zinc performs well as an ICCP anode but the service life of the zinc anode is directly related to the average current density used to operate the systems. After a ICCP system is turned off, the rebar in the concrete remains passive and protected for a period of time. Intermittent operation of CP systems is possible when continuous corrosion rate monitoring is used to identify conditions when the CP system needs to be turned on to reestablish protection conditions for the rebar. This approach applies CP protection only when needed and reflects the fact that external protection may not be needed for a range of environmental conditions. In doing so, intermittent CP would lower the average current necessary to protect rebar, increase the anode service life, and reduce the lifetime costs for protecting reinforced concrete bridges

High temperature corrosion research at the Albany Research Center

The Severe Environment Corrosion and Erosion Research Facility (SECERF) at the Albany Research Center is operational. SECERF consists of 6 modules that share the availability of up to 10 different gases to produce environments for high temperature corrosion and erosion research. Projects to be conducted in the modules include: corrosion sensors for fossil energy systems, thermal gradient effects on high temperature corrosion, the development of sulfidation resistant alloys, determination of the effects of ash on the corrosion of metals and alloys in coal and waste combustion and coal gasification environments, high temperature erosion-corrosion of metals, and molten slag effects on refractories. Results from two areas, the effect of ash deposits on alloy corrosion and thermal gradient effects on the corrosion of metals, will be highlighted. Ash produced in coal gasifiers, coal combustors, and waste combustors, when deposited on metal surfaces, provides sites for corrosion attack and contributes chemical species that participate in the corrosion reaction. Results are presented for the corrosion of 304L stainless steel, that was either uncoated or coated with ash or with ash containing NaCl or Na2SO4, in air-water vapor mixtures at 600 C. The presence of high heat fluxes and temperature gradients in many fossil energy systems creates the need for an understanding of their effects on corrosion and oxidation. Such information would be useful for both improved alloy design and for better translation of isothermal laboratory results to field use. Temperature gradients in a solid oxide result in two changes that modify diffusion within the oxide. The first is when a gradient in point defect concentration is created within the oxide, for example, where more vacancies are expected at a higher temperature. The second change is when the presence of a temperature gradient biases the diffusion jump of an atom. Results of tests are presented for cobalt with metal surface temperatures of approximately 920-950 C in N2 plus 1-10 vol% O2 environments with a heat flux of about 40 kW/m2. Non-equilibrium thermodynamics were used to develop oxidation rate equations in temperature gradients that were combined with point defect information of CoO to predict oxidation rates

Oxidation Resistance of Low Carbon Stainless Steel for Applications in Solid Oxide Fuel Cells

Alloys protected from corrosion by Cr2O3 (chromia) are recognized as potential replacements for LaCrO3–based ceramic materials currently used as bipolar separators (interconnects) in solid oxide fuel cells (SOFC). Stainless steels gain their corrosion resistance from the formation of chromia, when exposed to oxygen at elevated temperatures. Materials for interconnect applications must form uniform conductive oxide scales at 600–800o C while simultaneously exposed to air on the cathode side and mixtures of H2 - H2O, and, possibly, CHx and CO - CO2 on the anode side. In addition, they must possess good physical, mechanical, and thermal properties. Type 316L stainless steel was selected for the baseline study and development of an understanding of corrosion processes in complex gas environments. This paper discusses the oxidation resistance of 316L stainless steel exposed to dual SOFC environment for ~100 hours at ~900oK. The dual environment consisted of dry air on the cathode side of the specimen and a mixture of H2 and 3% H2O on the anode side. Post - corrosion surface evaluation involved the use of optical and scanning electron microscopy and x-ray diffraction analyses

Understanding the corrosion behavior of chromia-forming 316L stainless steel in dual oxidizing-reducing environment representative of SOFC interconnect

A and B site doped LaCrO3-based electronically conducting Perovskite ceramic materials have been extensively used as interconnects in solid oxide fule cells (SOFC) operating at 800° to 1000°C as the Perovskites offer good electrical conductivity, chemical compatibility with the adjacent components of the fuel cell, chemical stability in reducing and oxidizing atmospheres, and thermal expansion coefficients that match other cell components. However, requirements for good mechanical properties, electrical and thermal conductivities, and low cost make metallic interconnects more promising. Significant progress in reducing the operating temperature of SOFC from ~1000°C to ~750°C is expected to permit the use of metallic materials with substantial cost reduction. Among the commercially available metallic materials, Cr2O3 (chromia) scale-forming iron base alloys appear to be the most promising candidates since they can fulfill the technical and economical requirements. These alloys, however, remain prone to reactions with oxygen and water vapor at fuel cell operating conditions and formation of gaseous chromium oxides and oxyhydroxides. To study the degradation processes and corrosion mechanisms of commercial chromia scale-forming alloys under SOFC interconnect exposure conditions, 316L was selected for this research because of the availability of the materials. The dual environment to which the interconnect material was exposed consisted of dry air (simulates the cathode side environment) and a mixture of H2 and 3% H2O (simulates the anode side environment). Post-corrosion surface evaluation involved the use of optical and scanning electron microscopy, as well as energy dispersive X-ray analyses