Effect of Reactive Element Oxide Coatings on the High Temperature Oxidation Behavior of a FeCrAl Alloy

Thin coatings of nitrate‐converted oxides of Y, Zr, Hf, Ce, La, Ca, and Al have been applied to the surface of a Fe‐18 weight percent (w/o) Cr‐5 w/o Al alloy by hot‐dipping. The influence of these coatings on the oxidation behavior of the alloy was studied at 1100 and 1200°C. Results were also compared with the oxidation of a 1 w/o Hf‐containing alloy of the same base composition, with or without the application of selected coatings. It was found that all of the coated samples, apart from that coated with aluminum oxide, developed extremely convoluted scales. Oxide ridges several times larger than those formed on the untreated alloy developed at the oxidation temperature. These convoluted scales showed good spallation resistance after isothermal testing, but failed under thermal cyclic conditions. A thin layer of sulfur was found everywhere at the scale/alloy interface. The primary effect of the surface coatings was to increase the number of buckles in the oxide at the early stage of oxidation. Growth of the buckled oxide into large ridges took place by way of aluminum vapor phase transport and oxide lateral growth. The results are discussed in relation to the effect of reactive elements in improving scale adhesion, and it is suggested that the mechanisms governing this effect may be different for and for alloys.