A computational approach has been undertaken to design and assess potential Fe-Cr-Ni-Al systems to produce stable nanostructured corrosion-resistant coatings that form a protective, continuous scale of alumina or chromia at elevated temperatures. Phase diagram computation was modeled using the Thermo-Calc® software and database [1, 2] to generate pseudo-ternary Fe-Cr-Ni-Al phase diagrams to help identifying compositional ranges without undesirable brittle phases. Computational modeling of the grain growth process, sintering of voids, and interface toughness determination by indentation, assessed micro-structural stability and durability of the nanocoatings fabricated by a magnetron-sputtering process. Interdiffusion of Al, Cr, and Ni was performed using the DICTRA® diffusion code [3] to maximize the long-term stability of the nanocoatings. The computational results identified a new series of Fe-Cr-Ni-Al coatings that maintain long-term stability and a fine-grained microstructure at elevated temperatures. The formation of brittle sigma phase in Fe-Cr-Ni-Al alloys is suppressed for Al contents in excess of 4 wt.%. Grain growth modeling indicated that the columnar-grained structure with a high percentage of low-angle grain boundaries is resistant to grain growth. Sintering modeling indicated that the initial relative density of as-processed magnetron-sputtered coatings could achieve full density after a short thermal exposure or heat-treatment. Interface toughness computation indicated that Fe-Cr-Ni-Al nanocoatings exhibit high interface toughness in the range of 52–366 J/m2. Interdiffusion modeling using the DICTRA software package indicated that inward diffusion could result in substantial to moderate Al and Cr losses from the nanocoating to the substrate during long-term thermal exposures.
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ASME Turbo Expo 2009: Power for Land, Sea, and Air
June 8–12, 2009
Orlando, Florida, USA
Conference Sponsors:
- International Gas Turbine Institute
ISBN:
978-0-7918-4885-2
PROCEEDINGS PAPER
Computational Design of Corrosion-Resistant Fe-Cr-Ni-Al Nanocoatings for Power Generation
K. S. Chan,
K. S. Chan
Southwest Research Institute, San Antonio, TX
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W. Liang,
W. Liang
Southwest Research Institute, San Antonio, TX
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N. S. Cheruvu,
N. S. Cheruvu
Southwest Research Institute, San Antonio, TX
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D. W. Gandy
D. W. Gandy
Electric Power Research Institute, Charlotte, NC
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K. S. Chan
Southwest Research Institute, San Antonio, TX
W. Liang
Southwest Research Institute, San Antonio, TX
N. S. Cheruvu
Southwest Research Institute, San Antonio, TX
D. W. Gandy
Electric Power Research Institute, Charlotte, NC
Paper No:
GT2009-59111, pp. 747-757; 11 pages
Published Online:
February 16, 2010
Citation
Chan, KS, Liang, W, Cheruvu, NS, & Gandy, DW. "Computational Design of Corrosion-Resistant Fe-Cr-Ni-Al Nanocoatings for Power Generation." Proceedings of the ASME Turbo Expo 2009: Power for Land, Sea, and Air. Volume 4: Cycle Innovations; Industrial and Cogeneration; Manufacturing Materials and Metallurgy; Marine. Orlando, Florida, USA. June 8–12, 2009. pp. 747-757. ASME. https://doi.org/10.1115/GT2009-59111
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