Abstract
The mechanisms of oxide whisker growth and hot corrosion of 430 stainless steel (430SS) and aluminide 430 stainless steel hot-dipped in a Al–10 wt.%Si molten bath (430HDAS) were studied at 750 and 850 °C in air mixed with 500 and 990 vppm NaCl (g). The results showed that the loose Cr 2O 3 scale which formed on the 430SS could not prevent the corrosion of 430SS in a 500 vppm NaCl (g) atmosphere, resulting in the formation of Fe 2O 3 scale. Fe 2O 3 whiskers grew at the grain boundary of the Fe 2O 3 scale. However, no Fe 2O 3 whiskers formed on the Fe 2O 3 scale while 430SS was exposed in a 900 vppm NaCl (g) atmosphere. During the initial high-temperature corrosion of 430HDAS in a 500 vppm NaCl (g) atmosphere, a dense Al 2O 3 scale formed on the surface of the specimens. Also, Al 2O 3 whiskers grew on the Al 2O 3 scale. As exposure time increased, cyclic chlorination/oxidation degraded the protective aluminide layer and caused the formation of Fe 2O 3 scale and Fe 2O 3 whiskers. The morphology of Fe 2O 3 whiskers formed at 750 °C is more slender than those formed at 850 °C. The formation and growth of both Fe 2O 3 and Al 2O 3 whiskers may be attributed to the chloridation of both the steel substrate and aluminide layer, accelerating the diffusion rate of metallic ions in the oxide scales.
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