Full Content is available to subscribers

Subscribe/Learn More  >

Computational Design of Corrosion-Resistant Fe-Cr-Ni-Al Nanocoatings for Power Generation

[+] Author Affiliations
K. S. Chan, W. Liang, N. S. Cheruvu

Southwest Research Institute, San Antonio, TX

D. W. Gandy

Electric Power Research Institute, Charlotte, NC

Paper No. GT2009-59111, pp. 747-757; 11 pages
  • ASME Turbo Expo 2009: Power for Land, Sea, and Air
  • Volume 4: Cycle Innovations; Industrial and Cogeneration; Manufacturing Materials and Metallurgy; Marine
  • Orlando, Florida, USA, June 8–12, 2009
  • Conference Sponsors: International Gas Turbine Institute
  • ISBN: 978-0-7918-4885-2 | eISBN: 978-0-7918-3849-5
  • Copyright © 2009 by ASME


A computational approach has been undertaken to design and assess potential Fe-Cr-Ni-Al systems to produce stable nanostructured corrosion-resistant coatings that form a protective, continuous scale of alumina or chromia at elevated temperatures. Phase diagram computation was modeled using the Thermo-Calc® software and database [1, 2] to generate pseudo-ternary Fe-Cr-Ni-Al phase diagrams to help identifying compositional ranges without undesirable brittle phases. Computational modeling of the grain growth process, sintering of voids, and interface toughness determination by indentation, assessed micro-structural stability and durability of the nanocoatings fabricated by a magnetron-sputtering process. Interdiffusion of Al, Cr, and Ni was performed using the DICTRA® diffusion code [3] to maximize the long-term stability of the nanocoatings. The computational results identified a new series of Fe-Cr-Ni-Al coatings that maintain long-term stability and a fine-grained microstructure at elevated temperatures. The formation of brittle sigma phase in Fe-Cr-Ni-Al alloys is suppressed for Al contents in excess of 4 wt.%. Grain growth modeling indicated that the columnar-grained structure with a high percentage of low-angle grain boundaries is resistant to grain growth. Sintering modeling indicated that the initial relative density of as-processed magnetron-sputtered coatings could achieve full density after a short thermal exposure or heat-treatment. Interface toughness computation indicated that Fe-Cr-Ni-Al nanocoatings exhibit high interface toughness in the range of 52–366 J/m2 . Interdiffusion modeling using the DICTRA software package indicated that inward diffusion could result in substantial to moderate Al and Cr losses from the nanocoating to the substrate during long-term thermal exposures.

Copyright © 2009 by ASME



Interactive Graphics


Country-Specific Mortality and Growth Failure in Infancy and Yound Children and Association With Material Stature

Use interactive graphics and maps to view and sort country-specific infant and early dhildhood mortality and growth failure data and their association with maternal

Citing articles are presented as examples only. In non-demo SCM6 implementation, integration with CrossRef’s "Cited By" API will populate this tab (http://www.crossref.org/citedby.html).

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In