Composition, microstructure, and water vapor effects on internal/external oxidation of alumina-forming austenitic stainless steels

A family of creep-resistant austenitic stainless steels based on alumina (Al ₂O ₃) scale formation (AFA alloys) for superior high-temperature oxidation resistance was recently identified. Excellent oxidation behavior was observed at 650 and 700 °C in air with 10% water vapor. However, particularly at 800 °C, the presence of water vapor greatly increased the tendency for internal oxidation of Al. Water vapor also enhanced subscale Al depletion in some AFA alloys relative to dry air exposure. Increased levels of Nb additions were found to significantly improve oxidation resistance, as were reactive element additions of Hf and Y. Computational thermodynamic calculations of the austenitic matrix phase composition and the volume fraction of MC, B2-NiAl, and Fe ₂Nb base Laves phase precipitates were used to interpret oxidation behavior in terms of two-phase oxidation theory, reservoir effect, and the third-element effect of Cr. Of particular interest was the enrichment of Cr in the austenitic matrix phase by additions of Nb, which aided the establishment and maintenance of alumina. Higher levels of Nb additions also increased the volume fraction of B2-NiAl precipitates, which served as an Al reservoir during long-term oxidation. Implications of these findings for the design of AFA alloys with increased upper use temperature limits are discussed.