Critical factors affecting the high-temperature corrosion performance of iron aluminides

Iron aluminides are known to exhibit good-to-excellent corrosion resistance in a number of high-temperature environments. Under most conditions, this resistance derives from the establishment and maintenance of a sound and adherent alumina layer. Consequently the performance of iron aluminides under different aggressive high-temperature can be related to fundamental factors that affect the development, adhesion, and durability (lifetime) of protective alumina. Overall corrosion resistance depends not only on thermodynamic stability of the reaction product in a particular environment and its growth kinetics, but also on scale integrity and morphology, the chemical and physical nature of the oxide–metal interface, alloy strength, and the specific composition of the iron aluminide. Despite the multiplicity of factors, a relatively simple lifetime prediction model based on aluminum consumption can be used to evaluate the influences of changes in material parameters and to determine approaches to improving high-temperature corrosion resistance of iron aluminides.