The Effect of Thermal Expansion on Spallation Behavior of Fe-Base Alumina-Forming Alloys

Abstract

Long-term cyclic oxidation behavior was compared for commercial FeCrAl alloys and model Fe-Al and FeCrAl alloys, and their coefficients of thermal expansion (CTE) were measured. For single-phase disordered (ferritic) Fe(Al) alloys, the CTE increased only slightly with Al content and was similar to that of FeCrAl alloys. More significant CTE increases were observed at ≥20%Al, as intermetallic phases, Fe3Al and FeAl, formed. As expected, the intermetallic compositions showed increased oxide spallation rates during cyclic oxidation at 1100° and 1200°C. However, after extensive spallation and loss of Al from the substrate, the compositions of Fe3Al and FeAl specimens entered the ferritic phase field, and the amount of scale spallation decreased. Among commercial oxide dispersion strengthened (ODS) FeCrAl alloys, a composition containing Mo (ODM751) exhibited the lowest thermal expansion and showed the slowest degradation rate in long-term testing at 1100°C. The concept of minimizing CTE as a route for alloy development was investigated.