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Cast alumina-forming austenitic stainless steels have recently been developed at ORNL for use from about 750°C to 1150°C [2]. In a recent study Muralidharan et al discussed the effect of composition on the alumina-forming capability and creep properties of cast alloys of composition Fe- 25 wt.% Ni- 14 wt.% Cr-3.5 wt.% Al and with varying levels of Nb, Si, and C [3,4]. It was observed that alloys in this composition range containing about 25 wt. % Ni may be limited to operation at temperatures of about 800°C - 850°C depending on the water vapor levels in the environment due to inadequate oxidation resistance at higher temperatures. In a more recent study, Brady et al. [5] studied the ability of Feâ(25â45)Niâ (10â25)Crâ(4â5)Alâ1Siâ0.15Hfâ0.07Yâ0.01B wt% base alloys with and without Nb, Ti, and C additions to form a protective alumina scale at 1100 °C in air with 10% water vapor. It was found that Feâ35Niâ25Crâ4Al with additions of Nb, C showed promise as an alloy base for future development to achieve a cast alumina-forming austenitic alloy for use at temperatures exceeding 1100°C.
Oak Ridge National Laboratory has been working with industrial partners Duraloy Technologies, and MetalTek International and University of Wisconsin, Milwaukee to develop cast austenitic stainless steel compositions for use in ethylene cracking furnace applications. This presentation will outline the methodologies used in the development of the cast Fe-Ni-Cr-Al austenitic stainless steels, their microstructure, and highlight their high temperature oxidation resistance. In addition, the ability of these alloys to resist coking in an ethane steam cracking environment has been evaluated. This talk will outline the experimental setup, testing methodologies, and results from cyclic coking-decoking tests conducted on the developmental alloys. These results were compared to results from baseline 35Cr-45Ni alloys.
Research sponsored by ARPA-E, US Department of Energy, under Contract DE-AC05-00OR22725 with UT-Battelle, LLC.
- E. Munoz Gandarillas, K. M. Van Geem, Marie-Francoise Reyniers, Guy B. Marin, âInfluence of the Reactor Material Composition on Coke Formation during Ethane Steam Cracking,â Ind. Eng. Chem. Res. 2014, 53, 6358-6371.
- G. Muralidharan, Y. Yamamoto, and M. P. Brady, âCast Alumina Forming Austenitic Stainless Steels,â U.S. Patent 8, 431, 072 B2, April 30, 2013.
- G. Muralidharan, Y. Yamamoto, M. P. Brady, D. Leonard, B. A. Pint, D. Voke and R. Pankiw, (2015) âDevelopment of Cast Alumina-forming Austenitic Stainless Steel Alloys for use in High Temperature Process Environments,â NACE Paper C2015-6114, Houston, TX, presented at NACE Corrosion 2015, Dallas, TX, March 2015.
- G. Muralidharan, Y. Yamamoto, M. P. Brady, L. R. Walker, H. M. Meyer II, and D. N. Leonard, âDevelopment of Cast Alumina-Forming Austenitic Stainless Steelsâ JOM, First Online: September 6, 2016, DOI: 10.1007/s11837-016-2094-8.
- M.P. Brady, G. Muralidharan, Y. Yamamoto, and B. Pint, âDevelopment of 1100°C Capable Alumina-Forming Austenitic Alloys,â Oxid Met, DOI 10.1007/s11085-016-9667-3.
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