Papers by Author: Bruce A. Pint

Abstract: Alumina-forming alloys have been studied for over 50 years and are now needed for high efficiency power generation applications operating at higher temperatures. Especially in the presence of water vapor, alumina-forming alloys outperform conventional chromia-forming alloys above 1000°C. However, alloy mechanical behavior is a significant issue and alumina-forming alloy development has been limited. The opportunity for alloy development is discussed as well as thefactors that limit oxidation resistance, including alloy thermal expansion and optimizing reactive element additions. Finally, lifetime modeling is discussed for thick section components together with the need to address performance in more complex environments.

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.

Abstract: A family of creep-resistant, Al2O3-forming austenitic (AFA) stainless steels was recently developed. The alloys exhibit excellent oxidation resistance up to ∼800°C, but are susceptible to internal attack of Al at higher temperatures. In the present work, higher levels of Ni, Cr, Al, and Nb additions were found to correlate with improved oxidation behavior at 900°C in air. The alloys generally appeared to be initially capable of external Al2O3 scale formation, with a subsequent transition to internal attack of Al (internal oxidation and internal nitridation) that is dependent on alloy composition. Compositional profiles at the alloy/scale interface suggest that the transition to internal oxidation is preceded by subsurface depletion of Al in the lower-Al compositions. In higher Al-containing compositions, NiAl second-phase precipitates act as an Al reservoir, and Al depletion may not be a key factor. Alloy design directions to increase the upper-temperature limit of protective Al2O3 scale formation in these alloys are discussed.

Abstract: Planning for a U.S. test blanket module to operate in the internationally-sponsored ITER reactor has focused attention on the many coating and compatibility issues that will need to be solved before fusion energy moves from concept to commercial reality. Examples are given for (1) a dual-layer, electrically-resistant coating as a potential solution to reduce the magnetohydrodynamic pressure drop with liquid Li and (2) materials compatibility issues with eutectic Pb-Li for conventional alloys and SiC/SiC composites. Because of the reduced activity of Li in Pb-Li, a wider range of functional materials can be considered in this system. Nevertheless, an Al2O3 scale on FeCrAl was transformed to LiAlO2 after exposure to Pb-Li at 800°C.