A numerical simulation method is proposed to investigate the nonlinear growth of thermally grown oxide (TGO) on a novel coated steam dual-pipe system operating at 700 °C. Utilizing oxidation kinetics data from high-temperature water vapor experiments, the study examines interface stresses and morphology evolution, considering initial surface waviness and cooling temperature effects. The findings indicate that the parabolic law accurately describes the nonlinear growth of TGO during high-temperature water vapor oxidation, with the TGO growth oxidation rate constant being 4.5×10−4μm2/h. The growth rate of TGO thickness decreases with increasing oxidation duration. Stress concentrations are found to develop at TGO interfaces, particularly in regions with high curvature, and those with elevated wavy amplitudes. The primary factor influencing stress redistribution and morphology evolution is the wavy amplitude of the TGO. Additionally, variations in cooling temperature affect interface stresses along the axial direction of the pipe system during nonlinear oxidation, resulting in relatively minor changes in morphology.
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