The kinetics of carbon dissolution in polycrystalline iron foils have been determined from electrical resistance measurements. Reaction with methane at 10–100 Torr pressure has been carried out at temperatures in the range 766–1163 K. Incremental resistance changes for unit increase in carbon concentration have been determined for temperatures between 838 and 1163 K. Breaks in the specific resistivity increment curves occur at temperatures associated with (i) significant structural rearrangements in the metal, (ii) nucleation of precipitates and (iii) phase transitions.Three stages of reaction with different rate-determining steps have been identified. At temperatures up to 1023 K, the first-stage reaction occurs with zero activation energy and its rate-determining step is attributed either to the chemisorption of methane molecules or formation of adsorbed CH3 radicals. Between 913 and 1008 K it is followed by a second-stage reaction in which carbon diffusion in ferrite is rate-determining, with an activation energy of 176 ± 15 kJ mol–1. Above the Fe–C eutectoid temperature (996–1011 K) the first stage is followed by a third-stage reaction, for which it is proposed that dehydrogenation of methyl radicals is rate-determining with an activation energy of 190 ± 5 kJ mol–1. The first and third stages follow the Langmuir isotherm and an isosteric heat of adsorption of 170 ± 11 kJ mol–1 has been determined for the third-stage reaction.Carbide formation occurs in both the second- and third-stage reactions, and in the latter the total carbon uptake in γ-iron corresponds closely with the iron–iron carbide phase boundary. The significance of these results for the mechanism of carbon deposition in transition-metal–hydrocarbon systems is discussed.
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