Abstract
Protective coating is an effective way to extend materials’ high-temperature service life. In order to improve the high-temperature oxidation resistance of AISI 304 stainless steel, mullite films with different layers were successfully prepared by the sol-gel method and the sintering process on the surface of stainless steel. The effect of the film layers on the high-temperature oxidation resistance of stainless steel at 900 °C for 100 h was studied. The analysis results of oxidation kinetics, X-rays diffraction (XRD), scanning electron microscopy (SEM) and energy dispersive analysis (EDS) show that Al1.4Si0.3O2.7 mullite film effectively improved the high-temperature oxidation resistance of stainless steel. The sample with three-layer mullite film has the best high-temperature oxidation resistance. The mass gain and oxidation spalling mass are only 4.6% and 34.5% of those of the uncoated sample after 100 h cyclic oxidation at 900 °C. A chromium oxide layer was formed at the interface of mullite film and the substrate during the sintering process. The generation of selective Cr2O3 scale was promoted at the cyclic oxidation stage so that the sample with three-layers has excellent high-temperature oxidation resistance.
Highlights
AISI 304 stainless steel is widely used in traditional industrial fields such as automobile manufacturing, power equipment, petrochemical industry, etc, by virtue of its excellent comprehensive mechanical properties, corrosion and high-temperature oxidation resistance [1,2,3]
AISI 304 stainless steel will be oxidized at a faster rate when the temperature reaches 900 ◦C, which limits its application in a wider range [4,5,6]
For single-layer and three-layer mullite film samples (Figure 1a,b), the ground marks can be clearly observed, which indicates the thicknesses of films were relatively thin
Summary
AISI 304 stainless steel is widely used in traditional industrial fields such as automobile manufacturing, power equipment, petrochemical industry, etc, by virtue of its excellent comprehensive mechanical properties, corrosion and high-temperature oxidation resistance [1,2,3]. Mullite is a ceramic material composed of Al2O3 and SiO2, which has the characteristics of low expansion coefficient, high melting point, strong corrosion resistance and excellent thermal shock resistance [21,22,23,24,25]. It is a potential high-temperature engineering material [26,27,28,29,30] due to its excellent high-temperature performance, which makes it widely used in kiln linings, pipelines, and steam turbines. Different kinds of mullite materials are prepared and used for the water vapor corrosion at elevated temperature [29], hot gas and oily water cleaning and antibacterial biofilm
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