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High Temperature Corrosion of the Structural Materials and Degradation of Coatings in Harsh Conditions

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Corrosion".

Deadline for manuscript submissions: closed (31 December 2023) | Viewed by 11215

Special Issue Editors

Prof. Dr. Nigel Simms

E-Mail Website
Guest Editor
Centre for Thermal Energy Systems and Materials, Cranfield University, Cranfield, UK
Interests: biomass and waste; carbon capture and storage; fuels; power systems & turbines; surface engineering
Special Issues, Collections and Topics in MDPI journals
Dr. Tomasz Dudziak

E-Mail Website
Guest Editor
Łukasiewicz—Krakow Institute of Technology, Kraków, Malopolska, Poland
Interests: high temperature corrosion of Fe, Ni, TiAl based alloys; coating degradation; SEM, XRD, EDS analyses; corrosion; oxidation; fireside corrosion; pack cementation; coatings; surface engineering
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

I am pleased to inform you that MDPI’s Materials journal is announcing a Special Issue related to high temperature corrosion of the structural materials and degradation of coatings in harsh conditions. The problem of high temperature corrosion has been well known for years. There is no development of society without high temperature, as high temperature means better efficiency and higher performance; however, materials based on Fe, Ni, TiAl metal matrix fabricated in a standard way or by 3D technology possesses limitations. Therefore, it is extremely important to validate steels and alloys against high temperature applications. In order to prevent corrosion degradation and oxidation processes most frequently, protective coatings are needed to serve an extended lifetime for structural materials. I am inviting you to submit the very latest work on the subject, where high temperature corrosion steels alloy is a key subject of the research.

This Special Issue offers a timely and authoritative opportunity to present recent progress in the field of high temperature corrosion of the structural materials and degradation of coatings in harsh conditions. Furthermore, the Special Issue is expected to highlight exciting challenges and future applications of the new coating systems and 3D materials resistance against high temperature exposures in different atmospheres.

Prof. Dr. Nigel Simms
Dr. Tomasz Dudziak
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • oxidation, steam oxidation, sulphidation, fireside corrosion, carburisation
  • coatings (thermally sprayed, PVD, diffusion type coatings)
  • steels, Ni based alloys, TiAl alloys, co-based alloys
  • 3D printed materials for high temperature applications

Published Papers (7 papers)

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Research

20 pages, 11413 KiB  
Article
High Temperature Oxidation Behavior of Creep Resistant Steels in Water Vapour Containing Environments
by Mária Hagarová, Gabriela Baranová, Martin Fujda, Miloš Matvija, Peter Horňak, Jozef Bednarčík and Daria Yudina
Materials 2022, 15(2), 616; https://doi.org/10.3390/ma15020616 - 14 Jan 2022
Cited by 6 | Viewed by 1644
Abstract
This study describes the water vapour effect on the oxidation resistance of 9Cr creep resistant steels. Boiler P91 and MarBN steels were oxidized for 3000 h in a simulated humid atmosphere with ~10% water vapour. The oxidation kinetics had a stable course for [...] Read more.
This study describes the water vapour effect on the oxidation resistance of 9Cr creep resistant steels. Boiler P91 and MarBN steels were oxidized for 3000 h in a simulated humid atmosphere with ~10% water vapour. The oxidation kinetics had a stable course for 1000 h and was evaluated by the weight gain curves for both experimental steels and both oxidation temperatures. The oxidation rate was higher at 650 °C versus 600 °C, as reflected by the oxidation rate coefficient. A significant increase occurred after 1000 h of oxidation, which was related to the local breakdown oxide scale and oxide nodules were formed on steel. This oxidation behavior was influenced by the fact that a compact spinel structure of iron oxides and alloying elements were not formed on the steel. Analysis after 3000 h of exposure showed hematite Fe2O3 formed on the outer layer, magnetite Fe3O4 on the middle layer, and the bottom layer consisted of iron-chromium-spinel (Fe,Cr)2O3. Full article
(This article belongs to the Special Issue High Temperature Corrosion of the Structural Materials and Degradation of Coatings in Harsh Conditions)
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21 pages, 9054 KiB  
Article
Preliminary Studies on Rare Elements Addition and Effect on Oxidation Behaviour of Pack Cementation Coatings Deposited on Variety of Steels at High Temperature
by Tomasz Dudziak, Ewa Rząd, Tomasz Polczyk, Katrin Jahns, Wojciech Polkowski, Adelajda Polkowska and Michal Wójcicki
Materials 2021, 14(22), 6801; https://doi.org/10.3390/ma14226801 - 11 Nov 2021
Cited by 1 | Viewed by 1383
Abstract
The aim of the paper was to investigate the air oxidation behaviour of pack aluminised steels exposed at 650 °C for 1000 h in static natural air atmosphere. The pack coatings were doped by rare elements such as gadolinium (Gd), cerium oxide (CeO [...] Read more.
The aim of the paper was to investigate the air oxidation behaviour of pack aluminised steels exposed at 650 °C for 1000 h in static natural air atmosphere. The pack coatings were doped by rare elements such as gadolinium (Gd), cerium oxide (CeO2), and lanthanum (La) in order to enhance the corrosion resistance and plasticity of the deposited layers. In this work, the following steels were used: 16M, T91, VM12, Super 304H, and finally SANICRO25. The results indicated a much higher corrosion resistance in the coated 16M, T91, and VM12 steels; the steels with a higher Cr content than 16 wt % Cr indicated a better behaviour in the uncoated state than in the coated state. However, the observed difference in mass gain between the uncoated and the coated austenitic steels was not enormous. Furthermore, the addition of RE elements to the coating showed some effect in terms of coating thicknesses and differences in the layer structures. The materials prior to testing and after the exposure were investigated using XRD, the SEM X-ray maps with an EDS instrument were used for particular samples to evaluate the phase identifications, element concentrations, microstructure, and chemical composition. Full article
(This article belongs to the Special Issue High Temperature Corrosion of the Structural Materials and Degradation of Coatings in Harsh Conditions)
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10 pages, 4804 KiB  
Article
High Temperature Oxidation Behaviors of BaO/TiO2 Binary Oxide-Enhanced NiAl-Based Composites
by Bo Li, Ruipeng Gao, Hongjian Guo and Congmin Fan
Materials 2021, 14(21), 6510; https://doi.org/10.3390/ma14216510 - 29 Oct 2021
Cited by 1 | Viewed by 1001
Abstract
High temperature lubricating composites have been widely used in aerospace and other high-tech industries. In the actual application process, high temperature oxidation resistance is a very importance parameter. In this paper, BaO/TiO2-enhanced NiAl-based composites were prepared by vacuum hot-press sintering. The [...] Read more.
High temperature lubricating composites have been widely used in aerospace and other high-tech industries. In the actual application process, high temperature oxidation resistance is a very importance parameter. In this paper, BaO/TiO2-enhanced NiAl-based composites were prepared by vacuum hot-press sintering. The oxidation resistance performance of the composites at 800 °C was investigated. The composites exhibited very good sintered compactness and only a few pores were present. Meanwhile, the composite had excellent oxidation resistance properties due to the formation of a dense Al2O3 layer which could prevent further oxidation of the internal substrate; its oxidation mechanism was mainly decided by the outward diffusion of Al and the inward diffusion of O. The addition of BaO/TiO2 introduced more boundaries and made the Kp value increase from 1.2 × 10−14 g2/cm4 s to 3.3 × 10−14 g2/cm4 s, leading to a slight reduction in the oxidation resistance performance of the composites—although it was still excellent. Full article
(This article belongs to the Special Issue High Temperature Corrosion of the Structural Materials and Degradation of Coatings in Harsh Conditions)
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15 pages, 13202 KiB  
Article
Effect of Tensile Stress on the Oxide Properties of a Nickel-Based Alloy 600 in Simulated PWR Secondary Water
by Byung-Joon Bae, Jeoh Han, Jongsup Hong and Do-Haeng Hur
Materials 2021, 14(21), 6460; https://doi.org/10.3390/ma14216460 - 28 Oct 2021
Cited by 2 | Viewed by 1323
Abstract
The purpose of this work was to examine the effect of tensile stress on the oxide properties of a nickel-based Alloy 600 that was exposed to simulated nuclear steam generator water at 340 °C for 1000 h. The size of the outer oxide [...] Read more.
The purpose of this work was to examine the effect of tensile stress on the oxide properties of a nickel-based Alloy 600 that was exposed to simulated nuclear steam generator water at 340 °C for 1000 h. The size of the outer oxide particles increased, and the chromium content of the inner oxides decreased under tensile stress. Electrochemical measurements revealed that the charge carrier density increased, and the charge transfer resistance and film resistance were reduced under the tensile stress condition. These changes in the oxide properties are attributed to the formation of short diffusion paths such as line and surface defects due to tensile deformation. Full article
(This article belongs to the Special Issue High Temperature Corrosion of the Structural Materials and Degradation of Coatings in Harsh Conditions)
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17 pages, 1775 KiB  
Article
Mechanical-Chemical Coupling Effects on an Environmental Barrier Coating System under High-Temperature Water Vapour Conditions
by Dingjun Li, Fan Sun, Cheng Ye, Peng Jiang, Jianpu Zhang, Yiwen Chen and Xiaohu Yuan
Materials 2021, 14(19), 5907; https://doi.org/10.3390/ma14195907 - 08 Oct 2021
Viewed by 1490
Abstract
The degradation mechanisms for environmental barrier coatings (EBCs) under high-temperature water vapour conditions are vital for the service of aero-engine blades. This study proposes a theoretical model of high-temperature water vapour corrosion coupled with deformation, mass diffusion and chemical reaction based on the [...] Read more.
The degradation mechanisms for environmental barrier coatings (EBCs) under high-temperature water vapour conditions are vital for the service of aero-engine blades. This study proposes a theoretical model of high-temperature water vapour corrosion coupled with deformation, mass diffusion and chemical reaction based on the continuum thermodynamics and the actual water vapour corrosion mechanisms of an EBC system. The theoretical model is suitable for solving the stress and strain fields, water vapour concentration distribution and coating corrosion degree of an EBC system during the water vapour corrosion process. The results show that the thickness of the corrosion zone on the top of the EBC system depended on water vapour diffusion, which had the greatest influence on the corrosion process. The top corroded area of the rare-earth silicate EBC system was significantly evident, and there was a clear dividing line between the un-corroded and corroded regions. Full article
(This article belongs to the Special Issue High Temperature Corrosion of the Structural Materials and Degradation of Coatings in Harsh Conditions)
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17 pages, 6757 KiB  
Article
Sulfidation-Oxidation Resistance of Thermal Diffusion Multi-Layered Coatings on Steels
by Tomasz P. Dudziak, Ewa Rząd, Eugene Medvedovski and Gerardo Leal Mendoza
Materials 2021, 14(19), 5724; https://doi.org/10.3390/ma14195724 - 30 Sep 2021
Cited by 1 | Viewed by 1423
Abstract
The high-temperature sulfidation-oxidation corrosion resistance of protective coatings deposited on carbon and 316L steels was studied. The coatings obtained via the thermal diffusion process had multi-layered architectures and consisted of aluminides, iron borides, or iron boride–TiO2 layers. The protective coatings experienced a [...] Read more.
The high-temperature sulfidation-oxidation corrosion resistance of protective coatings deposited on carbon and 316L steels was studied. The coatings obtained via the thermal diffusion process had multi-layered architectures and consisted of aluminides, iron borides, or iron boride–TiO2 layers. The protective coatings experienced a minimal rate of mass changes, insignificant scale formation, and no delamination and surface micro-cracking after 504 h of exposure in 1% (Vol.) H2S-air atmosphere at 500 °C. Furthermore, the coatings demonstrated a high degree of integrity compared to bare 316L stainless steel. Aluminized steels demonstrated the highest performance among the studied materials. The developed thermal diffusion coatings are promising candidates due to their enhanced stability in H2S–air atmosphere; they may be employed for protection of inner and outer surfaces of long tubing and complex shape components. Full article
(This article belongs to the Special Issue High Temperature Corrosion of the Structural Materials and Degradation of Coatings in Harsh Conditions)
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10 pages, 40221 KiB  
Article
High-Temperature Oxidation Properties and Microstructural Evolution of Nanostructure Fe-Cr-Al ODS Alloys
by Zhengyuan Li, Lijia Chen, Haoyu Zhang and Siyu Liu
Materials 2021, 14(3), 526; https://doi.org/10.3390/ma14030526 - 22 Jan 2021
Cited by 4 | Viewed by 1880
Abstract
The oxidation behavior and microstructural evolution of the nanostructure of Fe-Cr-Al oxide dispersion strengthened (ODS) alloys prepared by spark plasma sintering were investigated by high-temperature oxidation experiments in air at 1200 °C for 100 h. The formation of Al2O3 scale [...] Read more.
The oxidation behavior and microstructural evolution of the nanostructure of Fe-Cr-Al oxide dispersion strengthened (ODS) alloys prepared by spark plasma sintering were investigated by high-temperature oxidation experiments in air at 1200 °C for 100 h. The formation of Al2O3 scale was observed by X-ray diffraction (XRD) and scanning electron microscopy (SEM) with energy-dispersive X-ray spectroscopy (EDS) line scans. The oxidation rate of Fe-Cr-Al ODS alloys is lower than that of conventional Fe-Cr-Al alloys, and the oxide layer formed on the Fe-Cr-Al alloy appeared loose and cracked, whereas the oxide layer formed on the Fe-Cr-Al ODS alloys was adherent and flat. This is due to the high density of dispersed nano-oxides hindering the diffusion of Al element and the formation of vacancies caused by them. In addition, the nano-oxides could also adhere to the oxide layer. Besides, the microstructure of the Fe-Cr-Al ODS alloy had excellent stability during high-temperature oxidation. Full article
(This article belongs to the Special Issue High Temperature Corrosion of the Structural Materials and Degradation of Coatings in Harsh Conditions)
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