Volatile products in the corrosion of Cr, Mo, Ti and four superalloys exposed to O2 containing H2O and gaseous NaCl
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Fryburg, G. C.↗
Engineering topics
Stearns, C. A.
Publications and source records attributed to Stearns, C. A..
Susceptibility to hot corrosion of four nickel-base superalloys, NASA-TRW VIA, B-1900, 713C and IN-738
The susceptibility to hot corrosion of four nickel-base, cast superalloys has been studied at 900 and 1000 C. The test consisted of coating alloy samples with known amounts of Na2SO4 and oxidizing the coated samples isothermally in 1 atmosphere of slowly flowing oxygen, the weight-gain being monitored on a sensitive recording microbalance. Susceptibility to hot corrosion decreased in the order of decreasing molybdenum content of the alloys. Preoxidation of samples before hot-corrosion testing markedly increased the induction period observed prior to the inception of hot corrosion for all alloys tested. X-ray diffraction analyses of the oxide scales were made. All samples that underwent hot corrosion showed the presence of a (Ni,Co)MoO4 layer near the alloy-oxide interface. Several specimens displayed resistance to hot corrosion and these showed NaTaO3 as a prominent feature in their oxide scale. Our results may be interpreted as indicating that molybdenum in an alloy is detrimental, with respect to hot corrosion, while tantalum is beneficial.
Stearns, C. A.↗
Oxidation in oxygen at 900 deg and 1000 deg C of four nickel-base cast superalloys: NASA-TRW VIA, B-1900, alloy 713C, and IN-738
The oxidation at 900 and 1,000 C of four nickel-base superalloys in 1 atmosphere of slowly flowing oxygen was investigated. Thermogravimetric rate data were obtained for periods to 100 hours. The morphology and composition of the oxide scales formed after 100 hours were studied by optical microscopy, X-ray diffraction, electron microprobe, scanning electron microscopy, and X-ray photoelectron spectroscopy (ESCA). Alloys B-1900 and VIA were found to be primarily alumina formers, though probably 25 percent of their surface was covered by CR2O3-containing oxides at 900 C. Alloys 713C and IN-738 were primarily chromia formers, though the surface of 713C at 1,000 C was covered with NiO, and the surface of IN-738 at both temperatures was covered with a thin layer of TiO2.
Fryburg, G. C.↗
Gaseous sodium sulfate formation in flames and flowing gas environments
Formation of Na2SO4(g) in flames and hot flowing gas systems was studied by high pressure, free-jet expansion, modulated molecular beam mass spectrometric sampling. Fuel-lean CH4-O2 flames doped with SO2, H2O and NaCl yielded the gaseous Na2SO4 molecule in residence times of less than one millisecond. Intermediate species NaSO2(g) and NaSO3(g) were also observed and measured. Composition profiles were obtained for all reaction products. Nonflame flowing gas experiments showed that Na2SO4 and NaSO3 gaseous molecules were formed at 1140 C in mixtures of O2, H2O(g), SO2 and NaCl(g). Experimental results are compared with calculated equilibrium thermodynamic predictions.
Stearns, C. A.↗
Volatile products in the corrosion of Cr, Mo, Ti and four superalloys exposed to O2 containing H2O and gaseous NaCl
Cooled target collection techniques were used to study the formation of volatile products when samples of Cr, Ti, IN-738, 713C, NASA-TRW VIA and B-1900 were exposed, at elevated temperatures, to oxidizing environments containing H2O(g) and NaCl(g). Samples were heated to 1050 C in one atmosphere of slowly flowing oxygen, saturated with water at 21 C, and containing about 50 ppm NaCl(g). Volatile products were detected for all materials except B-1900 and Ti. High pressure mass spectrometric sampling was used to directly identify volatile products emanating from samples of Cr and IN-738 subject to the above environments.
Fryburg, G. C.↗
Thermochemical analyses of the oxidative vaporization of metals and oxides by oxygen molecules and atoms
Equilibrium thermochemical analyses are employed to describe the vaporization processes of metals and metal oxides upon exposure to molecular and atomic oxygen. Specific analytic results for the chromium-, platinum-, aluminum-, and silicon-oxygen systems are presented. Maximum rates of oxidative vaporization predicted from the thermochemical considerations are compared with experimental results for chromium and platinum. The oxidative vaporization rates of chromium and platinum are considerably enhanced by oxygen atoms.
Kohl, F. J.↗
Formation of Na2SO4 and K2SO4 in flames doped with sulfur and alkali chlorides and carbonates
High pressure, free-jet expansion, mass spectrometric sampling was used to identify directly and to measure reaction products formed in doped methane-oxygen flames. Flames were doped with SO2 or CH3SH and sodium or potassium chlorides or carbonates. Gaseous NA2SO4 or K2S04 molecules were formed in residence times on the order of msec for each combination of dopants used. Composition profiles of combustion products were measured and compared with equilibrium thermodynamic calculations of product composition.
Fryburg, G. C.↗
Volatile products from the interaction of KCl(g) with Cr2O3 and LaCrO3 in oxidizing environments
Cooled target collection techniques and high pressure mass spectrometric sampling were used to measure the relative rates of oxidative vaporization and to identify the volatile products emanating from samples of chromia and Mg-doped lanthanum chromite. The materials were exposed to partial pressures of KCl with and without H2O in one atmosphere of slowly flowing oxygen at elevated temperatures. Chromia and fresh samples of lanthanum chromite exhibited enhanced rates of oxidative vaporization upon exposure to these reactants. Mass spectrometric identification showed that the enhancements resulted from the heterogeneous formation of complex molecules of the type KCl sub 1,2,3 CrO3 and KOH sub l,2 CrO3. Lanthanum chromite that had undergone prolonged oxidative vaporization exhibited no enhanced oxidation upon exposure to the reactants.
Kohl, F. J.↗
Interaction of NaCl(g) and HCl(g) with condensed NA2SO4
The interaction of Na2SO4(l) with NaCl(g), HCl(g) and H2O(g) was studied in atmospheric pressure flowing air and oxygen at Na2SO4(l) temperatures of 900 and 1000 C. Thermomicrogravimetric and high pressure mass spectrometric sampling techniques were used. Experimental results establish that previously reported enhanced rates of weight loss of Na2SO4(l) in the presence of NaCl(g) are due to the reaction: Na2SO4(c) + 2HCl(g) = 2NaCl(g) + SO2(g) + H2O(g) + 1/2O2(g) being driven to the right in flowing gas systems. The HCl(g) is the product of hydrolysis of NaCl caused by small but significant amounts of H2O(g) present in the system. Thermochemical calculations are used to show that even with sub-ppm levels of H2O(g) present, significant quantities of HCl(g) are produced.
Stearns, C. A.↗
High temperature environmental effects on metals
The gas turbine engine was used as an example to predict high temperature environmental attack on metals. Environmental attack in a gas turbine engine derives from high temperature, combustion products of the air and fuel burned, and impurities. Of all the modes of attack associated with impurity effects, hot corrosion was the most complicated mechanistically. Solutions to the hot corrosion problem were sought semi-empirically in: (1) improved alloys or ceramics; (2) protective surface coating; (3) use of additives to the engine environment; and (4) air/fuel cleanup to eliminate harmful impurities.
Grisaffe, S. J.↗
Reactions of chromium with gaseous NaCl in an oxygen environment
Target collection techniques and high pressure mass spectrometric sampling have been used to study the formation of volatile chromium-containing species in the reaction of Cr2O3 with O2 and NaCl gases. Experiments were performed at atmospheric pressure as a function of chromium temperature, oxygen pressure, and NaCl gas concentration. The major chromium-containing vapor species were found to be (NaCl)x CrO3 gas, with x = 1,2, and 3, which are products of heterogeneous reactions on the surface. The kinetics indicate first order dependence on oxygen and sodium chloride pressures.
Stearns, C. A.↗
Hot corrosion studies of four nickel-base superalloys: B-1900, NASA-TRW VIA, 713C and IN738
The susceptibility to hot corrosion of four nickel base superalloys has been studied at 900 deg and 1000 deg C in one atmosphere of slowly flowing oxygen. Hot corrosion was induced by coating the samples with known doses of NaSO4 and oxidizing the coated samples isothermally on a sensitive microbalance. In general, the order of susceptibility found was: B-1900 is greater than 713C is greater than NASA-TRW VIA and is greater than IN738. This order corresponds to the order of decreasing molybdenum content of the alloys. Chemical evidence for B-1900 indicates that hot corrosion is instigated by acid fluxing of the protective Al2O3 coating by MoO3.
Fryburg, G. C.↗
Hot corrosion studies of four nickel-base superalloys - B-1900, NASA-TRW VIA, 713C and IN738
The susceptibility to hot corrosion of four nickel-base superalloys has been studied at 900 and 1000 C in one atmosphere of slowly flowing oxygen. Hot corrosion was induced by coating the samples with known doses of Na2SO4 and oxidizing the coated samples isothermally on a sensitive microbalance. In order of decending susceptibility to hot corrosion, these alloys were ranked: B-1900, 713C, NASA-TRW VIA, IN738. This order corresponds to the order of decreasing molybdenum content of the alloys. Chemical evidence for B-1900 indicates that hot corrosion is instigated by acid fluxing of the protective Al2O3 coating by MoO3.
Fryburg, G. C.↗
Reactions of chromium with gaseous NaCl in an oxygen environment
Target collection techniques and high pressure mass spectrometric sampling have been used to study the formation of volatile chromium-containing species in the reaction of Cr2O3 in the condensed state with gaseous O2 and NaCl. Experiments were performed at atmospheric pressure as a function of chromium temperature, oxygen pressure, and NaCl concentration. The major chromium-containing vapor species were found to be (NaCl)xCrO3, with x = 1,2, and 3, which are products of heterogeneous reactions on the surface. The kinetics indicate first order dependence on oxygen and sodium chloride pressures.
Stearns, C. A.↗
Sodium sulfate - Vaporization thermodynamics and role in corrosive flames
Mass spectrometer experiments were conducted to determine the thermodynamic properties of gaseous Na2SO4, and these data were used in a computer program to calculate equilibrium flame compositions and temperatures for representative turbine engine and burner rig flames. The work is important in that sodium sulfate is the major phase recovered from turbine surfaces after instances of corrosion, due to the presence of sulfur in fuels and sodium chloride in intake air.
Kohl, F. J.↗
Oxidative vaporization kinetics of Cr2O3 in oxygen from 1000 to 1300 C
Rates of oxidative vaporization of Cr2O3 on preoxidized resistively heated chromium were determined in flowing oxygen at a pressure of 0.115 Torr for temperatures from 1000 to 1300 C. Reaction controlled rates were obtained from experimental rates by a gold calibration technique, and these rates were shown to agree with those predicted by thermochemical analysis. The activation energy obtained for the oxidative vaporization reaction corresponded numerically with the thermochemical enthalpy of the reaction. A theoretical equation is given for calculating the rate from thermodynamic data using boundary-layer theory.
Stearns, C. A.↗
Enhanced oxidative vaporization of Cr2O3 and chromium by oxygen atoms
Rates of oxidative vaporization of Cr2O3 have been found to be markedly enhanced in the presence of oxygen atoms. Investigations were conducted over the temperature range 200-1250 C. For Cr2O3 the enhancement was about 10 to the 9th power at 550 C in oxygen containing 2.5% atoms. Rapid oxidative vaporization of bare chromium was observed below 800 C, the rate being about one-half that of Cr2O3. Results are interpreted in terms of thermochemical analysis.
Fryburg, G. C.↗
Oxidative vaporization kinetics of chromium (III) oxide in oxygen from 1270 to 1570 K
Rates of oxidative vaporization of Cr2O3 on preoxidized resistively heated chromium were determined in flowing oxygen at 0.115 torr for temperatures from 1270 to 1570 K. Reaction controlled rates were obtained from experimental rates by a gold calibration technique. These rates were shown to agree with those predicted by thermochemical analysis. The activation energy obtained for the oxidative vaporation reaction corresponded numerically with the thermochemical enthalpy of the reaction. A theoretical equation is given for calculating the rate from thermodynamic data by using boundary layer theory.
Stearns, C. A.↗