In this paper, the development of surface oxide scale and the evolvement of spallation mechanism of Fe-21Cr-5.6Al super alloy were investigated at 1200°C and 1300°C. The oxidation kinetic curves were obtained by isothermally measuring the weight gain of alloy oxidized with various time durations. The morphologies of oxide scale and grain structures were observed by SEM/EDX, and the phase structure was analyzed by XRD. The results show that the oxidation processes follow the parabolic law and the oxidation rate is higher at 1300°C than 1200°C. Though the FeCrAl alloy shows capabilities against oxidation even at a high temperature of 1300°C, the oxidation behavior and mechanism are distinct from those at moderate temperatures (<1000°C). Different morphologies and phase structure were found in oxide scales generated at different temperatures within the same time duration. Typical buckling was observed in the super alloy when it was subjected to 1200°C. Equiaixed grains with multiple voids were found near the alloy surface. At 1300°C, a flat and thicker oxide layer was formed. The grains were stretched vertically against the alloy and presented as coarse and compact near the interface. The vertically stretching of grain was triggered by fast element transportation inside the alloy. The differences in grain morphologies among the different test temperatures demonstrated that although the super alloy followed parabolic law at both test temperatures, the oxidation processes were different due to the evolvement of grain morphologies and oxide scale structures caused by exposure to high temperature.

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