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P92 is one of the important steels for super heater tubes used in combustion plants. However, in fossil fuel fired environments the formation of oxides and sulfides are challenging the material. To understand early corrosion mechanisms, which are important for process prediction, high temperature in-situ ageing experiments of Fe-Cr-Mn alloys in SO2 and SO2+H2O atmosphere were performed, applying energy dispersive X-ray diffraction (EDXRD) analysis.
The ageing of Fe-Cr model alloys in 0.5 % SO2 and 99.5 % Ar atmosphere was investigated to aim in a fundamental and systematic analysis of the combined oxidation and sulfidation mechanism. The crystallization and reaction paths for oxide and sulfide formation were followed in-situ by energy dispersive X-ray diffraction (EDXRD) in an early stage of corrosion (30 s – 24 h). For this technique, high energetic white synchrotron X-ray radiation (10-100 keV) was used as radiation source. Diffraction pattern were collected continuously in an early stage of corrosion up to 24 h during the complete ageing experiment.
The crystalline phases, growing on top of the coupons, were identified directly via their specific dhkl values. The evolution of the extracted integral intensities of specific reflections of the corrosion products as a function of time access direct information about the kinetics of the nucleation and growth. The results presented here show for iron with 2 wt% Cr wuestite formation first. Wuestite vanishes after 10 min of reaction only and magnetite and hematite appear. Magnetite formation proceeds simultaneously with sulfide formation. Sulfides growth proceeds after an incubation time, which differs for low alloyed (2 wt% Cr) and high alloyed (9 wt% Cr) material.
The ageing of Fe-Cr model alloys in 0.5 % SO2 and 99.5 % Ar atmosphere was investigated to aim in a fundamental and systematic analysis of the combined oxidation and sulfidation mechanism. The crystallization and reaction paths for oxide and sulfide formation were followed in-situ by energy dispersive X-ray diffraction (EDXRD) in an early stage of corrosion (30 s – 24 h). For this technique, high energetic white synchrotron X-ray radiation (10-100 keV) was used as radiation source. Diffraction pattern were collected continuously in an early stage of corrosion up to 24 h during the complete ageing experiment.
The crystalline phases, growing on top of the coupons, were identified directly via their specific dhkl values. The evolution of the extracted integral intensities of specific reflections of the corrosion products as a function of time access direct information about the kinetics of the nucleation and growth. The results presented here show for iron with 2 wt% Cr wuestite formation first. Wuestite vanishes after 10 min of reaction only and magnetite and hematite appear. Magnetite formation proceeds simultaneously with sulfide formation. Sulfides growth proceeds after an incubation time, which differs for low alloyed (2 wt% Cr) and high alloyed (9 wt% Cr) material.
Ferritic-martensitic high temperature alloys are widely used as boiler tube and heat exchanger materials in combustion based power plants. All technologies have in common that the applied materials are exposed to different temperatures, process pressures and reactive atmospheres which lead to a change of the material properties and a further degradation of the material.
To date corrosion analytics mainly proceeds via the use of various microscopic techniques and the analysis of the corrosion products after the reaction is completed. Comprehensive efforts have been made to study high temperature corrosion by the use of environmental SEM’s or in-situ TEM technologies. The here presented work will show a different approach to study high temperature gas corrosion in a multiple gas atmosphere by energy dispersive X-ray diffraction (EDXRD). For this technique high energetic white X-ray radiation (10-100 keV) was used as radiation source instead of conventional monochromatic radiation. It enables us to study crystallization procedures on short and medium time scales (1 min < t < 24 h) and the collection of Bragg-Signals of the phases of interest as a function of process time. Their occurrence can directly be correlated with thermodynamic and kinetic parameters. A special designed corrosion reactor was used to combine high temperature gas corrosion experiments with the collection of diffraction patter. The crystallization and reaction paths for oxide and sulfide formation was followed in-situ on Fe-Cr and Fe-Cr-Mn model alloys in a hot SO2 containing (T=650 °C) atmosphere.
Melanised cell walls and extracellular polymeric matrices protect rock-inhabiting microcolonial fungi from hostile environmental conditions. How extracellular polymeric substances (EPS) perform this protective role was investigated by following development of the model microcolonial black fungus Knufia petricola A95 grown as a sub-aerial biofilm. Extracellular substances were extracted with NaOH/formaldehyde and the structures of two excreted polymers studied by methylation as well as NMR analyses. The main polysaccharide (~ 80%) was pullulan, also known as α-1,4-; α-1,6-glucan, with different degrees of polymerisation. Αlpha-(1,4)-linked-Glcp and α-(1,6)-linked-Glcp were present in the molar ratios of 2:1. A branched galactofuromannan with an α-(1,2)-linked Manp main chain and a β-(1,6)-linked Galf side chain formed a minor fraction (~ 20%). To further understand the roles of EPS in the weathering of minerals and rocks, viscosity along with corrosive properties were studied using atomic force microscopy (AFM). The kinetic viscosity of extracellular K. petricola A95 polysaccharides (≈ 0.97 × 10-6 m2 s-1) ranged from the equivalent of 2% (w/v) to 5% glycerine, and could thus profoundly affect diffusion-dominated processes. The corrosive nature of rock-inhabiting fungal EPS was also demonstrated by its effects on the aluminium coating of the AFM cantilever and the silicon layer below.
Electrochemically active bacteria such as iron oxidizing bacteria (IOB) or iron reducing bacteria (IRB) accelerate the corrosion of stainless steel via the oxidation and reduction of iron oxides in the passive layer. The exposure to medium containing IOB and IRB leads to pitting corrosion with deep pits on stainless steel surfaces. Improving corrosion control via a better understanding of localized corrosion processes is highly relevant especially for reasons of safety or environmental protection since advancing pitting corrosion can easily lead to unpredictable material failure. Classic electrochemical methods however, provide insufficient information about the spatial heterogeneity of a corroding sample and fall short in detecting localized corrosion.
The aim of this work is to develop methods for the analysis of localized corrosion, on stainless steel surfaces induced by IRB and IOB biofilms. It is quite challenging to address the complexity of the variations in the passive layer composition and microstructure as well as the biofilm’s complexity with its local differential aeration cells and electrochemical parameters both at the same time. Thus in this study, agarose artificial biofilms mimicking the physical properties of a natural biofilm have been used as model systems to be able to differentiate between individual effects. This artificial biofilm is applied on a multi-electrode stainless steel sample to identify local anodic sites during exposure experiments. For more detailed analysis of active sites, a scanning electrochemical microscopy (SECM) has been applied. Using the SECM as an amperometric sensor, we have investigated concentration gradients of iron ions or oxygen within the biofilm and its immediate vicinity on actively corroding electrodes.
The presented analytical approach delivers promising results in clarifying how localized corrosion of stainless steels develops chronologically and spatially in the presence of IRBs and IOBs. Our results on model systems do also provide the basis for the investigation of natural biofilms in the future.
Metal reducing bacteria (MRB) are capable of utilizing different metals, such as iron, chromium, manganese or uranium as well as many organic compounds, as electron acceptors for their metabolism. Via direct and indirect electron transfer processes MRB are able to convert insoluble passive film species like Fe(III)-oxides to soluble Fe(II)-oxides and hydroxides. This weakening of the passive film not only leads to an acceleration of the general corrosion processes, but also increases the susceptibility of stainless steels to pitting corrosion. Electron transfer mechanisms are not yet fully understood and the role of bacteria in corrosion processes is controversially discussed in the literature. Moreover, recent research indicates that the secretion of electron shuttles like riboflavins by MRB also contributes to the extracellular electron transfer.
This project aims at clarifying the chemical and electrochemical interaction mechanisms of MRB with stainless steel surfaces. To investigate the changes in the oxide chemistry on the stainless steel surface in the presence of biomolecules and MRB a new flow cell has been designed and constructed which enables the collection of XANES (X-ray Absorption Near Edge Structure) spectra in fluorescence mode at the Fe K-edge and electrochemical analysis. Availability of oxygen and the pre-exposure of the MRB to Fe(III) during cultivation have been investigated as parameters with significant effect on the corrosion rates. XANES analysis is supplemented by ex-situ X-Ray Photoelectron Spectroscopy (XPS) and Fourier Transform Infrared Reflection Absorption Spectroscopy (FT-IRRAS) to complete the surface characterisation in terms of the oxide chemistry and the composition of organic residues. Complementary electrochemical quartz crystal microbalance (e-QCM) measurements have been performed to quantify the kinetics of bacterial attachment and biofilm formation. Together with the frequency shift, the evolution of the dissipation signal has been analyzed to investigate the changes in viscosity and structure of the biofilm from initial stages up to maturation. Scanning Electron Microscopy (SEM) and Atomic Force Microscopy (AFM) has been used to study the structure and viscoelastic properties of the biofilms after e-QCM experiments.
The presentation will summarize our results on the effects of individual surface and environment related parameters on the chemical/electrochemical interaction mechanisms of MRB leading to passive film degradation on stainless steel surfaces and provide useful insights from a fundamental aspect for the development of novel mitigation strategies for microbiologically influenced corrosion.
Multielectrodes are arrays of single electrodes arranged in a particular geometry. In our work, all the single electrodes are identical stainless steel X5CrNi18-10 (1.4301) wire electrodes. Using a multielectrode analyser all single electrodes are connected via zero resistance ammeters, simulating a galvanically coupled single electrode surface. The advantage of the multielectrode analyser (MMA) is that the currents flowing between single electrodes can be measured. Thus, real-time maps can be generated indicating where anodic and cathodic areas lie on the surface of the multielectrode and how they behave.
The combination of the multielectrode analyser with the scanning electrochemical microscopy (SECM) enables the identification of corrosion sites and the detailed electrochemical analysis.