PNNL-14116

Materials Properties Database for Selection of High-Temperature Alloys and Concepts of Alloy Design for SOFC Applications
Z.G. Yang D.M. Paxton K.S. Weil J.W. Stevenson P. Singh

November 2002

Prepared for the U.S. Department of Energy under Contract DE-AC06-76RL01830

DISCLAIMER This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor Battelle Memorial Institute, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof, or Battelle Memorial Institute. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.

PACIFIC NORTHWEST NATIONAL LABORATORY operated by BATTELLE for the UNITED STATES DEPARTMENT OF ENERGY under Contract DE-AC06-76RL01830

Printed in the United States of America Available to DOE and DOE contractors from the Office of Scientific and Technical Information, P.O. Box 62, Oak Ridge, TN 37831-0062; ph: (865) 576-8401 fax: (865) 576-5728 email: reports@adonis.osti.gov Available to the public from the National Technical Information Service, U.S. Department of Commerce, 5285 Port Royal Rd., Springfield, VA 22161 ph: (800) 553-6847 fax: (703) 605-6900 email: orders@ntis.fedworld.gov online ordering: http://www.ntis.gov/ordering.htm

This document was printed on recycled paper.

(8/00)

PNNL-14116

Materials Properties Database for Selection of High-Temperature Alloys and Concepts of Alloy Design for SOFC Applications

ZG Yang DM Paxton KS Weil JW Stevenson P Singh

November 2002

Pacific Northwest National Laboratory Richland, Washington 99352

Abstract
To serve as an interconnect / gas separator in an SOFC stack, an alloy should demonstrate the ability to provide (i) bulk and surface stability against oxidation and corrosion during prolonged exposure to the fuel cell environment, (ii) thermal expansion compatibility with the other stack components, (iii) chemical compatibility with adjacent stack components, (iv) high electrical conductivity of the surface reaction products, (v) mechanical reliability and durability at cell exposure conditions, (vii) good manufacturability, processability and fabricability, and (viii) cost effectiveness. As the first step of this approach, a composition and property database was compiled for high temperature alloys in order to assist in determining which alloys offer the most promise for SOFC interconnect applications in terms of oxidation and corrosion resistance. The high temperature alloys of interest included Ni-, Fe-, Co-base superalloys, Cr-base alloys, and stainless steels. In the US alone, there are hundreds of commercial compositions produced, over 250 of which are listed in Appendix A. Two initial criteria (oxidation resistance and oxide scale electrical conductivity) were used to reduce the list of alloys to manageable proportions. Thermal expansion and fabrication characteristics were then considered to further reduce the list of stainless steels. Due to their outstanding oxidation resistance and their potential to be used in SOFC components that can exclude alumina scales from the stack electrical path, alloys with a sufficient amount of aluminum were classified into a separate alumina-forming alloy category. The down-selected compositions (approx. 130 in number) and their characteristics and/or applications are listed in the Selected Alloy Compositions tables (Appendix B). Following the down-selection of alloy compositions, materials properties of interest corresponding to the their functional requirements in SOFC stacks were compiled in a tabular form (Appendix C). For comparison, the properties of selected noble metals and intermetallics were also collected and compiled and are listed in a separate table in Appendix C. Analysis of the pertinent literature indicated that, for a wide variety of alloys, there remains a lack of information on specific materials properties. Also, we have observed a large scatter in the reported database. For those cases, we employed general alloying principles as a tool of choice to approximate the unavailable data and to evaluate the reliability and consistency of collected data. Though numerous high temperature alloys look promising, it is anticipated that there will be few, if any, off the shelf alloy compositions which could completely satisfy the materials requirements as an interconnect, especially for a long term in a specific SOFC design. Therefore, some concepts of alloy design, including composition, constitution, and structure, as well as their effects on properties relevant to SOFC applications, are elaborated in an attempt to provide guidance for modification of current compositions and development of new alloys. Acknowledgement: This work was funded by the U.S. Department of Energys National Energy Technology Laboratory (NETL) under the Core Technology Program (CTP) of the Solid-State Energy Conversion Alliance (SECA).

Table of Contents
I. II. III. IV. V. Introduction . 2 5 10 18 24 26 28 49 61

Selection of alloy compositions ..... Alloy Properties relevant to the SOFC interconnect application Effects of alloy elements Conclusions References ..

Appendix A: Compositions of High Temperature Alloy.. Appendix B: Selected Alloy Compositions Appendix C: Properties of Selected Alloys ..

I.

Introduction

Over the past several years, advances in planar anode-supported cell designs, along with improvements in the cell component materials and fabrication processes, have led to a steady improvement in the electrical performance, performance stability and reliability of planar SOFCs. The use of thin electrolytes and advanced cell electrode configurations and materials has led to a steady reduction in the operating temperatures to the 800C range or lower, without compromising the electrical performance or reliability. Both metallic and ceramic interconnect materials have been used in SOFC stacks to demonstrate the feasibility of relatively long term operation of planar cells. Results indicate that although electronically conducting ceramic current collectors demonstrate superior chemical and structural stability; they remain very expensive and difficult to fabricate. Metallic current collectors, on the other hand, show surface oxide formation, increase in resistance and contamination of adjoining cell components. Metallic current collectors, however, remain highly cost effective and easy to fabricate when compared with ceramic counterparts. In a planar SOFC configuration, the current collector / bipolar gas separator, as the name indicates, acts as a separator for the fuel and the oxidant gases and also serves as a current collector between cells. The fuel gas environment, consisting of H2, H2O, CO, CO2, CHx, etc., has a low oxygen partial pressure ( Log PO2 (atm) = -14 to -20) and high carbon activity, while the oxidant gas environment usually consists of air. Exposure to this dual environment leads to oxidation and corrosion of metals and alloys resulting in the formation of various corrosion products. Bipolar separators also are exposed to peripheral gas seals (glass or compressive) and may experience chemical interaction with the seal materials. Until recently, the leading candidate material for the SOFC interconnect was electronically conducting doped lanthanum chromite, LaCrO3, a ceramic which could easily withstand the 1000C operating temperature of an electrolyte or air electrodesupported SOFC design. CVD-EVD as well as high temperature sintering techniques were initially used for the fabrication of dense interconnections. Liquid phase sintering and dopants were also investigated to promote sintering at lower temperatures. However, difficulties with obtaining high-density chromite parts at reasonable sintering temperatures persisted. It was also found that the chromite interconnect tended to partially reduce at the fuel gas/interconnect interface, causing the component to warp and the peripheral seal to break. Development of the lower temperature anode supported cells which utilize nickel-based anode supports, thin electrolytes and highly active cathode structures have caused lanthanum chromite to be supplanted by metallic interconnects as the interconnect material of choice. Compared to doped lanthanum chromite, high temperature metallic materials also offer advantages such as improved manufacturability, significantly lower raw material and fabrication costs, and higher electrical and thermal conductivity. However, for a metallic alloy to be considered as a candidate material for the interconnect, it must satisfy the following requirements: Good surface stability (resistance to oxidation, sulfidation, and carburization) in both cathodic (air) and anodic (fuel gas plus

water vapor) atmospheres during isothermal and thermal cyclic operations. Thermal expansion matching to the other stack components (as least for a rigid seal design). Chemical compatibility with other materials in contact with the interconnect such as seals and cell materials. High electrical conductivity through both the bulk material and in-situ formed oxide scales. Mechanical reliability and durability at the devices operating temperature. Strong adhesion or bond strength between the as-formed oxide scale and the underlying alloy substrate. Good manufacturability.

While there is a general agreement among the researchers in the SOFC technology development area that a suitable metal-based SOFC interconnect is needed for the overall cost reduction and faster start up, there is no agreement as to what alloy system might form the basis for this sub-component. Furthermore, there is no conclusive study that has been published in the open literature on suitable lower temperature SOFC interconnect materials that could serve as a reference. Long term degradation issues such as oxidation, carburization, sensitization, localized grain boundary penetration and oxide scale spallation still remain unresolved for a variety of alloys during their long term exposure under fuel cell operating conditions. The time, effort, and expense of developing a new alloy also needs basic understanding of the above degradation processes. Considering the above materials requirements, oxidation-resistant alloys and several noble metals, such as platinum (including surface coatings), could be initially considered as potential candidates. The high cost of platinum and other noble metals, however, preclude their use as an interconnect in planar SOFCs. The remaining choices would be high temperature alloys that demonstrate oxidation resistance at elevated temperatures. The high temperature alloys of interest include Ni-, Fe- and Co-base superalloys, Cr-base alloys, and the stainless steels. In the US alone, hundreds of commercial high temperature alloy compositions remain available for consideration for SOFC applications. To choose the best candidates for SOFC applications, and provide a reference for future research and development, the establishment of a materials database for the alloys of interest appeared to be mandatory. As the first step to build the materials database for high temperature alloys, hundreds of commercial compositions, as listed in Appendix A, were collected from sources including textbooks, handbooks, electronic databases and producer Internet homepages. Both the alloy name and its UNS (Unified Numbering System) No., developed jointly by the U.S. Society of Automotive Engineers (SAE) and the American Society of Testing and Materials (ASTM), are listed with its composition. As the first cut, a selection criterion involving the content of critical elements (Cr, Al) in the alloys was established and applied to reduce the original composition lists to manageable proportions. The selected compositions with their characteristics and traditional applications are tabulated in Appendix B. The properties relevant to the functional requirements were defined and collected (as comprehensively as possible) for the 3

selected alloys (Appendix C). Given the wide range of data sources consulted, it was recognized that questions regarding the reliability and consistency of the collected data were likely to arise. Therefore, general background knowledge of alloying principles and the relationships between alloy composition, structure and properties were reviewed and used to help evaluate the real potential of compositions for SOFC applications. The selection criteria for the different categories of alloy compositions are discussed below. Selected properties relevant to the interconnect materials requirements are also reviewed and discussed below in terms of general alloy principles. The concepts of alloy design are also elaborated, in an attempt to provide guidance for the modification of currently available compositions and future development of new alloy compositions exhibiting improved materials performance as an interconnect in SOFC.

II.

Selection of Alloy Compositions

As mentioned above, the obvious choice for the current collector material would be a high temperature alloy that provides oxidation resistance under the high temperature exposure conditions that characterize the SOFC environment. Nominally, high temperature alloys can be classified into Ni-, Fe- and Co-based superalloys, Cr-based alloys and stainless steels. All of these alloys typically contain Cr and Al, which provide oxidation resistance by forming thin, adherent protective layers of Cr2O3 and Al2O3, respectively. Because of the overall higher resistance of alumina scales, it appears that Al2O3 forming alloys may not be suitable to be used as interconnects, at least for some designs, because of the performance loss (voltage loss across the insulating alumina scale). Thus, it is necessary to establish critical minimum Cr contents and critical maximum Al contents needed for long-term protection. (It should be noted that alumina formers may find application in SOFC stack designs which can exclude the alumina scale from the current collection function within the stack). 1. Ni-, Fe-, and Co-Base Superalloys Superalloys, usually based on group VIIIA elements, have been developed for elevated temperature service where relatively severe mechanical stresses are encountered and high surface stability is required. These alloys are structurally characterized by the austenitic FCC matrix plus a variety of secondary phases. The principal secondary phases are the carbides MC, M23C6, M6C and M7C3 (rare) in all Ni-, Fe-(Ni-) and Co-base alloys, and FCC ordered Ni3(Al,Ti) intermetallic compound in only Ni- and Fe-(Ni)- base compositions. In the following, a selection criterion, mainly consisting of the critical minimum Cr content and critical maximum Al content is established for Ni-, Fe-, and Co-base superalloys. 1) Critical Minimum of Cr% Ni- and Fe-Base Superalloys: As suggested by Robb, Wasielewski, Giggins and Pettit [1,2], the critical minimum Cr content to ensure the formation of a protective, continuous Cr2O3 scale is approximately 20-25 wt% chromium. This critical amount of Cr is also required to prevent the rupture of the protective scale, and internal oxidation due to the depletion of chromium at the sub-surface. This suggested critical minimum is consistent with the work of Birks and Rickert [12], who concluded that the oxide scale consists primarily of Cr2O3 when the Cr content in the alloy is greater that 20%; spinel (Cr,M)3O4 phases tend to form when the Cr concentration is less than 10%. Furthermore, a Cr content of more than 20 wt% in Ni-, Fe-, and Co-base alloys has been recommended as the principal method for combating hot corrosion [3]. For Ni-base alloys, Sims et al. [4] concluded that at least 15 wt% Cr (i)

was needed for reasonable resistance to hot corrosion and that the optimum was 18-19 wt%. It should also be noted that, in addition to Cr and Al, trace elements such as La, Ce, Y, etc., might also directly or indirectly contribute, sometimes significantly, to the oxidation and corrosion resistance. For Ni-base alloys with Cr contents less than 20%, an appropriate amount of Al is typically added to enhance the oxidation resistance. Thus it appears that, for optimum oxidation and corrosion resistance, the Cr content in Ni- and Fe-base alloys should be more than ~18 wt%, which is therefore recommended as the critical minimum content for Ni- and Fe-base superalloys. (ii) Co-Based Superalloys:

Experimental studies conducted by Kofstad and Hed [5-7] indicated that additions of 9% Cr decrease the already poor oxidation resistance of pure cobalt by a factor of three. The oxide scale is predominantly CoO, with some CoCr2O4. Upon further additions of Cr to 25%, the oxidation rate decreases to a minimum, and a protective scale of Cr2O3 is established. Sims et al. [4] mentioned an optimum content of 25-30% Cr in Co-base alloys for hot corrosion. It is also noted that oxidation and corrosion resistance of Co-base alloys could be further improved by additions of Al, B, Ca, and Zr. Therefore, the critical minimum content of Cr was set as 22% for Co-base alloys. 2) Critical Maximum of Al% (i) Ni- and Fe-Base Superalloys:

Based on the ratio of Cr and Al, Wasielewski and Rapp[1] classified superalloys containing both Cr and Al into the following three categories: a) A NiO scale with Cr2O3 and Al2O3 internal oxides for both low Cr and Al contents-type I; b) An Cr2O3 scale with Al2O3 internal oxides for high Cr (>15%) but low Al (1%<Al%<3%)-type II; c) An exclusive -Al2O3 scale for relatively high Cr (>15%), and high Al (>3%)-type III. The steady-state parabolic rate constants are decreased by more than one order of magnitude in passing from type I to type II, and again in passing from type II to type III. The elimination of NiO as the steady-state scale is accomplished when the combined volume fraction of Cr2O3 and Al2O3 precipitates is sufficient to block inward diffusion of oxygen into the alloy matrix. Thus the sidewise growth of Cr2O3 particles can develop a protective inner scale of Cr2O3. The presence of an inner layer drastically reduces the local oxygen activity at the metal-interface so that an enrichment of Al2O3 particles occurs. For type III alloys, which have sufficient bulk Al or volume fraction of alumina, an -

Al2O3 layer forms beneath the Cr2O3 inner scale, which dramatically enhances the oxidation resistance, but acts as an electrical insulating layer. Therefore, an Al content of 3 wt% was established here to be the critical maximum. It was found that in the original list (Appendix A), no Nibase alloys with Cr content of higher that 18 wt% contain an Al content of higher than 3 wt%. For Fe-base alloys, application of this critical maximum only eliminates Incoloy MA956 with 4.5% Al, which is listed in the alumina forming alloys. Recent studies by Quadakkers et al [8] confirm that MA 956 is not suitable for typical SOFC interconnect applications due to the high electrical resistance of the formed alumina-scale. (ii) Co-Base Superalloys:

Normally, conventional Co-base alloys do not contain Al and depend on -Cr2O3 for protection. Note that, due to formability considerations, the casting alloys are left out for consideration at this stage. Only wrought alloys are listed here. Besides Cr and Al, Si is another alloy element that can provide oxidation resistance (by forming an insulating SiO2 layer.) No criterion was established in term of Si content, but its effect on oxidation should be considered for some listed compositions that contain a fairly large amount of Si. 2. Cr-Base Alloys The Cr-base alloys crystallize in the body-centered-cubic (BCC) structure and thus are not considered as superalloys by most metallurgists. As aluminum is not included in these compositions, no criterion was established, and thus all the Cr-alloys in the original list were considered to be selected for property collection. 3. Stainless Steels Stainless steel is a generic term covering a large group of alloys, which are commonly known for their oxidation resistance. In terms of their structures, stainless steels are usually divided into four groups: (i) ferritic steels; (ii) austenitic stainless steels; (iii) martensitic steels and (iv) precipitation-hardening steels. It is noted that some FCC austenitic stainless steels, usually with significant amount of Ni addition, are classified into superalloys and listed in FeNi-base superalloy tables. The ferritic stainless steels typically have 11 to 30% chromium as the major alloy addition and are low in carbon. These compositions are substantially ferritic, a body-centered-cubic (BCC) structure at all temperatures and therefore can not be strengthened by heat treatment, although some of the ferritic grades do undergo some austenite formation at high temperatures and can transform into

martensite. Ductility and formability of ferritic compositions are less than that of the austenitic grades. Their corrosion resistance competes with the austenitic grades for certain applications. Ferritic stainless steels are magnetic, and resistance to high-temperature corrosion is better than that of martensitic types. They generally have good ductility and can be welded or fabricated without difficulty. The aforementioned ferritic stainless steels also include pure or superferritic ones (refer to details in Part III, 5)), such as 29-4, E-Brite 26-1, etc., and ferritic/austenitic duplex structures, such as Carpenter 7-Mo, AL 255, etc. The ratio of ferrite (BCC) to austenite (FCC) in duplex structures mainly depend on the nickel content, which is typically in the range of 4.5 to 8%. This nickel content is not sufficient to generate a fully austenitic structure, thus resulting in a combination of BCC ferritic and FCC austenitic structures. Recently, some ferritic stainless steels have specifically been developed for glass sealing applications, where a close TEC match in the whole temperature range is required. Due to oxidation resistance considerations, only those with chromium content higher than the minimum are listed in the table of ferritic stainless steels. Austenitic steels with a FCC structure are characterized by larger linear thermal expansion coefficients, which are typically in 18~2010-6/K (RT~800oC). For example, Project 70 Stainless and Carpenter 21Cr-6Ni-9Mn are common standard and non-standard austenitic stainless steels and have linear thermal expansion coefficients of 19.010-6/K and 20.010-6/K (RT~760oC) [10], respectively. Thus all standard and non-standard austenitic compositions are unlikely to be satisfactory candidates for rigid seal stack designs. Martensitic and precipitation-hardening steels, which typically contain a Cr content of less than 18%,[9] were not included in this study; their maximum service temperature without excessive scaling is usually less than 650oC[11]. Therefore only ferritic standard and non-standard steels, including duplex structures, are evaluated using the same criterion in chemical composition as established for superalloys, i.e. the critical minimum Cr content is set at 18 wt% and the critical maximum Al content at 3 wt%. 4. Alumina Forming Alloys It has long been known that the oxidation resistance of alloys with a fairly high amount of Al is orders of magnitude higher than an alloy only containing Cr. It might be possible to make use of these alloys in SOFC stacks by designing the components to exclude the insulating alumina scale from the current conduction path. In this case, a minimum Al content (with reference to the Cr content) should be established. By referring to the previously mentioned Wasielewski and Robb rule[1] for classification of superalloys, the following criteria were established to create an alumina forming alloy table: i) High Cr (>18%) and high Al (>3%)- type I; ii) High Cr (>18%) and fairly high Al (1<Al%<3%) type II; iii) Fairly high Cr % (15~18%) and high Al (>3%) - type III.

It is expected that both type I and III will form continuous Al2O3 inner layers. For type II, the Al content may not be enough to form a continuous Al2O3 layer, but might be a major component in the oxide scale to improve the oxidation resistance. In this work, alloys with Cr%15 and Al%3 are defined as alumina formers and separated into the Table of Alumina Forming Alloys.

III. Alloy Properties Relevant to the SOFC Interconnect Application

According to the materials functional requirements for a metallic interconnect in SOFCs, the following parameters or properties must be used to evaluate alloys: (i) thermal expansion coefficient; (ii) electrical conductivity of both bulk matrix and scale; (iii) oxidation resistance; (iv) corrosion resistance; (v) yield strength; (vii) elastic modulus; (viii) formability or tensile elongation; (ix) cost; (x) other properties, such as hydrogen embrittlement resistance, machinability, and etc. For this study, it was expected that it would not be possible to obtain all data required. Also, some data might not be reliable, particularly if considerable scatter existed in data taken from different sources. In those cases, knowledge of alloying principles can be used as a tool to approximate the unavailable data and to evaluate the reliability and consistency of collected data. In the following, the parameters or properties corresponding to the materials functional requirements will be reviewed and discussed in terms of general alloying principles. 1) Thermal expansion coefficient (TEC)

When available, the average linear TEC over the temperature range of RT-800oC has been collected from the available literature data for a large number of Ni, Fe, Co and Cr base alloys. The TEC of alloy systems largely depend on the crystal lattice structure. In term of matrix crystal structure, high temperature alloys can also be classified into BCC ferritic and FCC austenitic formers, as shown schematically in Figure 1. Ni-, Fe-, Co-base superalloys and austenitic stainless steels are FCC formers; ferritic stainless steels as well as Cr-base alloys are BCC formers. As a rule of thumb, BCC formers have a lower TEC than FCC formers. For example, the TEC of pure ferritic stainless steels are typically in the range of 12.0~13.010-6 K-1 from RT to 800oC, therefore having a better thermal expansion match to typical SOFC components. If the concentrations of substitutional elements are increased beyond the phase stability region, austenite may be formed in the ferritic matrix, resulting in a duplex structure. All duplex stainless compositions have shown higher TEC than their pure ferritic counterparts. Fully austenitic alloys with FCC structure possess higher thermal expansion coefficients than BCC formers. Austenite stainless steels and Fe-base superalloys usually have a TEC in the range of 15.0~20.010-6 K-1 from RT800oC. Ni-base superalloys, also with FCC structure, tend to have TEC in the range of 14.0~19.010-6.K-1from RT to 800oC. Co-base superalloy compositions normally possess a TEC of 14.0~17.010-6 K-1 from RT to 800oC. The TEC data of different groups of alloys, along with other properties, is outlined in Table I.

10

Fe
Ferritic stainless steels Austenitic stainless steels

Potential compositions

FSS

Fe-base superalloys ASS

FeBSA Cr-base alloys BCC NiBSA FCC Ni-base superalloys

BCC + FCC CrBA

Cr
Figure 1. Schematic of alloy design for SOFC applications. Table I. Comparison of key properties of different alloy groups for SOFC applications Alloys CrBA FSS ASS Matrix TEC structure 10-6.K-1 BCC 11.0-12.5 BCC FCC 11.5-14.0 Oxidation resistance Good Good Good Good Good Mechanical strengths High Low Fairly high High High Manufacturability Difficult Fairly readily Readily Readily Readily Expensive Cost Very expensive Cheap Cheap Fairly expensive

Ni

(RT-800oC) (RT-800oC) (RT-800oC) (RT-800oC) (RT-800oC)

18.0-20.0 15.0-20.0 14.0-19.0

FeBSA FCC NiBSA FCC

11

2)

Electrical conductivity

For high temperature alloys, the electrical resistance increases with increasing temperature and is the sum of two parts, bulk resistance and scale resistance. The bulk electrical resistance, which usually can be easily found in handbooks and electronic sources, is collected and listed in Appendix C; typical values are 60-13010-6 .cm at RT with only slight increases with temperature. In the long term, the electrical resistance of the scale usually dominates the electrical behavior of high temperature alloys during SOFC operation. As mentioned earlier, the scale could be either Cr2O3 or Al2O3. Cr2O3 is an electronic conductor, which at 900oC has a conductivity of 10-2~10-1 S.cm-1 [16]. The temperature dependence of the conductivity can be expressed by: = o exp (-Ea/RT) where = conductivity ( = 1/, where = resistivity), Ea is the activation energy, R is the gas constant, and T is absolute temperature. o and Ea were reported by Kofstad et al. [15~17] at 0.04-0.06 S/cm and Ea=180 KJ/mol, respectively, in a temperature range of 800-1,000oC. Though the literature values of the electrical conductivity of alumina (-Al2O3) show large discrepancies and vary by many orders of magnitude [16], it is universally acknowledged to be an electrical insulator. Kofstad and Bredesen [21] concluded that the electrical conductivity of alumina is lower than that of chromia by a factor of 105-106. Accordingly, chromia formers rather than alumina formers should be considered as interconnect materials, unless the SOFC stack design excludes the Al2O3 scale from the electrical path. In principle, the area specific resistance (ASR) can be evaluated according to Cr2O3 scale thickness, which is a function of the rate constant, temperature and time, assuming the scale growth follows the parabolic law. This ASR estimation however yields a lower value than those reported in most recent studies [14,18~20, 22]. Almost all of these studies concluded that the Cr2O3 scale growth and thus the electrical resistance would reach an unacceptable level in the long term under the SOFC operating conditions. It is believed that the discrepancy is caused by the complexity of Cr2O3 scale growth, which will be described in the next section. The growth of Cr2O3 scales on high temperature alloys in practical environments is much more complicated than the growth on pure chromium, which is generally used in lab-studies to obtain the rate constant. Overall, it appears that, in the long term, the bulk and/or surface compositions of high temperature resistant alloys must be engineered to decrease the oxide scale growth rate and/or modify the scale chemistry so that the resistance of the scale can be limited to acceptable levels (refer to details in Part IV).

12

3)

Oxidation resistance

In Wagners theory of oxidation [23, 24], it is assumed that during the oxide growth, the transport of oxygen ions and/or metallic cations through the oxide scale takes place by lattice diffusion. Thus the growth of the surface oxide scale follows the well-known parabolic law: X 2 = kt + X o2 where X and X0 is the thickness of the scale at time t and t=0, respectively; k is rate constant. It has been experimentally shown that the parabolic law of the growth of scale is valid for essentially all cases in which the scale is adequately thick and homogeneous. It has been noted that[13] the net current flow in SOFCs may cause some deviation from the parabolic law prediction. Recent studies conducted on SOFC-related oxidation of high temperature alloys indicate that in most cases the oxidation of high temperature alloys still obeys the parabolic law under current flows appropriate for SOFC [14]. Hence, in this study, the parabolic rate constant is selected as the parameter measuring the oxidation resistance of high temperature alloys. Our literature survey indicates that data collected from textbooks, handbooks, and electronic data sources exhibit considerable scatter. In spite of the lack of consistent and complete data, the oxidation resistance can still be qualitatively understood in regard to alloy chemical composition. As stated previously, Cr and Al (and Si) are the major oxide scale formers to provide oxidation resistance in the high temperature alloys. The growth rate constant of Al containing alloys can be orders of magnitude lower that that of Cr containing alloys. Thus alumina formers typically have much higher oxidation resistance than alloys containing only chromium to provide protection. Besides, it is also common for the alumina formers to possess a stronger adherence between the scale and bulk matrix than chromia formers, and thus they demonstrate better scaling resistance against oxide spallation and cracking under thermal cycling. Weak bonding of chromia scales with the underlying substrate is dictated by the following growth features [15]: (i) The scales grow predominantly by outward chromium diffusion along grain boundaries in the chromia scale. But, there is also some inward oxygen diffusion to result in formation of oxide within the scale, which can cause growth stress in the scale. As the result of growth stress and the growth mechanism, the scales are often convoluted and contain cavities and porosity; furthermore, the scales often detach locally from the metal substrate Chromia scales may also exhibit extensive cracking at high temperatures and may also spall on cooling and thermal cycling.

(ii) (iii)

The use of so called reactive elements, such as Ce, La and Y, or their oxide forms, has been found to greatly modify this growth behavior, which will be discussed in detail in Part IV. As a result, alloys with additions of reactive

13

elements typically possess much improved oxidation, electrical and scaling resistance. 4) Corrosion resistance

The SOFC operates at high temperature (700-1,000oC) with fuel (such as H2 or reformed natural gas) on the anode side and air on the cathode side. Moisture could be present on both the cathode and anode sides, and, therefore, in contact with the metallic interconnects. Sulfur impurities present in the fuel gas stream are also expected to exist, although upstream desulfurization has been commonly applied to decrease the sulfur impurity level to sub ppm or ppb levels. Thus, besides oxidation, the interconnect could also suffer from sulfidation, hot corrosion (in the presence of molten salt), and carburization, etc. Thermal stresses generated in the SOFC stack due to large temperature gradients across the current collector could also accelerate the corrosion process due to premature cracking and spallation of the oxide scale. The presence of complex gaseous species in the fuel environment also result in the establishment of grain boundary corrosion, internal oxidation and localized metal loss resulting in overall reduction of component life. Sulfidation refers to an aggressive attack resulting from the combined effects of oxidation plus reactions with sulfur, which may be present in the fuel gas stream. Our literature search indicated that no standardized data is available for quantitative comparison. Thus only qualitative classification is currently possible within the scope of this report. Generally, the degree of sulfidation or hot corrosion can be related to the chromium content and alloy chemistry in Ni-, Fe- and Co-base alloys. The effect of alloy elements on hot corrosion resistance is also discussed in the Effects of Alloying Elements section below. 5) Yield strength

The metallic interconnect is also required to have enough strength to help maintain the structural integrity of the stack during SOFC operation at high temperatures and under thermal cycling. Accordingly, the high temperature alloys for an interconnect should possess thermal fatigue resistance against possible structural fracture during thermal cycling, creep resistance to maintain the dimensional stability at high operating temperature, and rupture resistance to endure peak thermal stresses generated during SOFC operation. All the aforementioned strengths can be more or less correlated to the yield strength, yield. For stainless steels, the compositions with higher yield strength usually possess higher creep and fatigue strengths, so do superalloys. The high temperature mechanical properties of some superalloys and stainless steel compositions are collected in Table II. Thus the yield strength, which is also easily available, was used to represent mechanical strength of the alloys. Since most alloys except annealed low carbon steels do not have obvious yielding strains, the stress at 0.2% is defined as the yield strength, 0.2. When possible, the yield strength from bar tests

14

at both RT and a high temperature (preferable around 800C) was collected. If bar test data was not available, sheet test data was used. The yield strength of an alloy is a function of alloy composition, phase constitution and structure/microstructure. The alloy can be strengthened through combinations of the following mechanisms: (i) Solution strengthening; (ii) Precipitation hardening; (iii)Martensitic hardening; (iv) Carbide or added oxide strengthening; (v) Work hardening. Different alloy groups could have different combinations of strengthening mechanisms. For example, strengthening mechanisms for ferritic stainless steels are limited to work hardening and solution strengthening, in order to maintain their BCC ferritic structure. Precipitation hardening may also be applicable, but may not be useful in improving the strength of an alloy at elevated temperatures (e.g., 800C). Overall, the superalloys and Cr-base alloys tend to have higher yield strengths than stainless steels; austenitic stainless and martensitic steels have higher yield strengths than ferritic stainless steels. The conventional ferritic stainless steels such as 430, 446, and 453 usually have a yield strength of about 300 MPa at RT. The yield strength of these stainless steels, however, drops quickly as the temperature increases over 700oC and usually ends up a number less than 50 MPa at 800oC. Consequently, these stainless compositions are typically characterized by substantially low creep and fatigue strength, which may be of concern for SOFC applications, especially in the long term. In past years, numerous stainless alloy compositions have been developed for improved strength by increasing Cr content and adding other alloy elements, such as Mo. In order to maintain their ferritic structure, the interstitial elements of C and N are controlled at a very low level (usually <0.015%) by using novel refining process such as argon-oxygen decarburization (AOD) or vacuum melting. These structures with improved properties are called superferritic stainless steels. For instance, the AL 29-4 series, which are characterized by a high content of chromium, addition of molybdenum, and limited concentration of interstitial elements C and N through AOD refining, possess a yield strength almost twice of that of conventional ferritic stainless steels.

15

Table II. High temperature mechanical properties of superalloy and stainless steels Alloys Elastic modulus (GPa) Yield strength 0.2 (MPa) 138 at 815oC 148 at 800oC 115 at 760oC 169 at 800oC 160 at 760oC 144 at 816oC 200 at RT 220 at 760oC 110 at 750oC 752 at 760o 421 at 760o 241 at 760o 275* at RT 55* at 760oC 345 at RT 41 at 760oC 310 at RT 48 at 760oC 290 at RT 58 at 760oC Creep strength T (MPa)
C 1732 =36 10
5 o

Rupture strength tT (MPa)

C 1816 =59 10
3 o

Superalloys Carpenter 19-9DL Incoloy 556TM Aktiebolag 253 MA Haynes R-41 Inconel 625 Pyromet 680 Stainless steels AL 446

C 1760 =59 10
5

C 1760 =29 10
5

C 1732 =234 10
3

C 1816 =165 10
3

C 1760 =234 10
3

C 1816 =96 10
3

C 1732 =55 10
5

C 1816 =62 10
3

C 1760 =7.6 10
5

C 1760 =13.5 10
3

Carpenter 443 200 at RT AL 439 HPTM AL 441 HPTM 200 at RT 200 at RT

C 1704 =7.0 10
4

C 1816 =7.0 10
3

C 1816 =11.0 10
3

* Minimum as required. 6) Elastic modulus

The elastic modulus at RT and high temperature was collected and listed for most of the alloy compositions. Typically the superalloys have an elastic modulus in the vicinity of 200 GPa, although the moduli of specific polycrystalline alloys can vary from 170~240 GPa at room temperature depending on the alloy systems. Ferritic stainless steels also have moduli around 200 GPa. The elastic modulus decreases at high temperatures. 7) Joinability

No standard parameter and data are available to quantitatively measure the joinability of various metals or metals and ceramics of interest. Overall, alloys 16

with a FCC matrix structure, such as superalloys, have better joinability than those with a BCC matrix, such as Cr-base alloys. Ni- and Fe-Ni-base superalloys are considerably less weldable that the Co-based superalloys. Austenitic stainless steels have better joinability than ferritic stainless steels, which may be exhibit the following difficulties: (i) Excessive grain growth at high temperature; (ii) Sensitization when the steel is cooled from temperatures above 925oC; (iii) Lack of ductility. 8) Formability

Conventionally, the Erichsen or Olsen cupping depth (mm) is used to measure the formability. If the E or O cupping depth at room temperature (RT) was not available, the elongation data from bar tests, which is available from many sources, is collected as an alternative for evaluation. Generally, alloys with higher elongation rate are expected to have better formability. Overall, superalloys and stainless steels are better than Cr-base alloys. 9) Cost

The price of stainless steel 446 (in mils sheet) is used as the basis. The cost factor is defined as the ratio of the price of a specified alloy to that of 446. Superalloys are more expensive than stainless steels and among various superalloys, Co-base alloys are more expensive than Ni-base; Ni-base alloys are more expensive than Fe-base. Mechanically alloyed compositions are more expensive than their conventional counterparts. 10) Others, including resistance to hydrogen embrittlement, and machinability.

BCC matrix alloys are typically more sensitive to hydrogen-induced embrittlement than FCC matrix alloys. Machinability of alloys is expressed as a percentage by referring to Seco Tools AB. Decreasing values indicate increasing machining difficulty. The machining ability of stainless steels can be summarized as the followings: (i) (ii) (iii) (iv) The martensitic stainless steels are usually machined in the annealed conditions. Their machinability is generally intermediate to the ferritic and austenitic grades; The ferritic grades are easiest to machine; The austenitic grades are gummy and give the most difficulty; Improved machinability (in all cases) can be obtained through addition of lead, sulfur, or phosphorus.

17

IV. Effects of Alloy Elements

Alloy properties are determined by alloying compositions, phase constitution, and structure. Alloying elements and their quantity are the most important factors to be considered in the alloy design for the desired structure and thus the required properties. Cr, Ni and Fe are three major alloy elements in high temperature alloys. As shown in Figure 1, the quantities of these three elements in an alloy could decide the phase constitution, structure and thus properties. As mentioned previously, Cr is a primary element for forming oxide scales for providing surface stability of high temperature alloys. To have enough oxidation and corrosion resistance at the SOFC operating temperatures, ideally the amount of Cr in most high temperature alloys should not be less than a number around 18%, as described previously. In addition, Cr is also an important element for improving mechanical properties through solid solution strengthening and carbide hardening by forming Cr7C3 and Cr23C6. In Fe-base high temperature alloys, including superalloys and stainless steels, Cr, by producing the gamma loop in Fe-Cr phase diagram (Figure 2), can be utilized to stabilize ferrites and destabilize austenite. For the pure Fe-Cr system, a minimum of 13 wt% Cr is required to maintain the BCC ferritic structure from RT to the melting point. For martensitic stainless steels, the Cr content cannot be too high, normally less than 18%, in order to generate austenite at high temperatures, which transforms to martensite during subsequent cooling. In Cr-base alloys, a BCC crystal structure is maintained which contributes to thermal expansion matching with other SOFC components. Though the addition of more Cr increases the oxidation resistance and also helps stabilize the BCC ferritic structure for a TEC match, increased Cr concentration could also lead to some disadvantages for SOFC applications. As shown in the Fe-Cr phase diagram in Figure 2, a second phase, called the sigma phase, can precipitate along grain boundaries in the alloy matrix at a temperature in the range of 550~870oC when the concentration of Cr is higher than 14~15 wt% [11]. The formation of sigma phase along grain boundaries not only causes a lower ductility (sigma phase embrittlement), but also results in deteriorated oxidation resistance as well as thermal expansion mismatch in SOFC, as indicated in our recent studies[25]. It is also reported that increasing Cr contents in ferritic structures decrease the thermal expansion coefficient of alloy compositions, but also creates knees in the thermal expansion curves if the Cr concentration becomes too high [26]. As indicated by many studies [14,18~20, 22], the resistance of the chromia scale will reach an unacceptable level after hundreds of hours under current SOFC operating conditions. Accordingly, it appears that the high temperature alloys have to be modified so as to inhibit the growth of the chromia scale and decrease the resistance of the scale. One effective approach is to change the bulk or surface chemistry by adding reactive elements, such as Y, Ce, or La (or their oxide forms). These elements, when added as a trace amount (0~0.1%) to the alloys, significantly modify the growth behavior of the chromia scale, as listed by Kofstad [15] in the following: (i) The preferential formation of chromia scales is enhanced; (ii) The growth rate of chromia scales is reduced; (iii) The adherence of chromia scales to the alloy substrate is improved; (iv) The scales are denser.

18

Figure 2. Cr-Fe phase diagram and crystal structure data. (After J.O. Anderson and B. Sundman [27] )

19

As a result, theses reactive trace elements significantly increase the oxidation resistance of alloys, decrease electrical resistance of the scale, and improve the scaling resistance under thermal cycling. Another approach to inhibit the growth of the chromia scale is to modify the surface of currently available compositions by applying a dense coating, whose composition is usually a conductive oxide, acting as a diffusion barrier to decrease the growth of chromia layer. The coatings are also expected to decrease or prevent the evaporation of chromia scale [32,33]. Vaporized chromium species can deposit at the interface of the cathode and electrolyte, resulting in higher polarization by decreasing the active sites at the interface [34]. Ideally, the conductive oxide used for the coating should be an electronic conductor with very low ionic conductivity ion order to decrease cationic and anionic transport through the coating layer. Coatings with perovskite oxides traditionally used in SOFC have demonstrated promising results in improving the surface stability of chromia forming alloys [22, 28-31]. Besides Cr, Al and Si are the other two elements that can be used to provide oxidation resistance. It has been demonstrated that Al is much more effective than Cr in improving oxidation, corrosion and scaling resistance by forming an Al2O3 layer on the high temperature alloys. The alumina formed on the alloy surface is also thermodynamically stable and thus does not exhibit the poisoning effects associated with the evaporation of species from the chromia scale. The insulating nature of the alumina scale, however, may prevent any application of alumina formers in the active electrochemical area of the cell. Due to the lack of adherence and susceptibility to internal oxidation, Si is not commonly used in alloying to provide oxidation resistance. It is also postulated that the silica based or silica containing scale could become very insulating in the active cell region resulting in performance loss. Ni acts to stabilize the austenite structure and form ordered precipitation for strengthening of Ni- and Fe-base superalloys. Thus in the ferritic structures, the Ni amount must be controlled at a lower level (typically less than about 2~3.0% for ferritic stainless steels, but dependent on content of Cr, C, N, etc.) in order to maintain their BCC crystal structure even at high temperatures. With increases in the amount of Ni, the alloy matrix will transform from BCC to FCC. The thermal expansion coefficients of FCC alloys might be too high for consideration for SOFC applications (at least for stacks utilizing rigid, bonded seals (e.g., glass, glass-ceramic seals)). Fe is the base element for the stainless steels and Fe-base superalloys. Below 912oC, pure Fe has a BCC ferritic structure and transforms to FCC austenitic structure after this point. As discussed earlier, Cr helps to stabilize the BCC ferritic structure. By the contrast, Ni, Mn, Mo, Co and many other substitutional elements help stabilize the FCC austenitic structure by pushing the gamma loop in the Cr-rich direction. Another important function of Fe is to form Fe3C in steels and also act as a solid solution strengthener. Mo, W, Ti, Nb and Ta are carbide formers and usually used to improve mechanical strength. Interstitial elements of C and N can also play important role in alloy design. Both elements can be used to strengthening alloy matrix through interstitial solution hardening mechanism and also helps formation of austenites by moving the gamma loop to the Cr

20

rich direction. So, in the ferritic structure, the content of these interstitial elements should be controlled at a limited level. Some trace elements, such as phosphorus and sulfur, typically have detrimental effects on alloy properties, but could modify manufacturability. Their quantity is usually closely controlled in most compositions. The effects of alloy elements are summarized in Table III.

21

Table III. Effects of alloying elements on properties relevant to SOFC applications Composition range Alloying
Elements
Ni/FeBSA CoBSA SS CrBSA These elements are the base elements for high temperature alloys. Besides they are used for strengthening and/or improving mechanical strength. Base element for NiBSA; Stabilizes FCC austenite and increase TEC; Be less that 2.0 for BCC ferritic structures with lower TEC; Form hardening precipitates to increase mechanical strength for Ni-/Fe-BSA. Base element for FeBSA and SS, usually cheaper than Ni, Coand Cr-bases; Improve mechanical strength through solid solution strengthening and carbide (Fe3C) formation. Base element for Co-base alloys, expensive; Raises solvus temperature to affect amount of precipitates; Improve mechanical strength w/ solid solution strengthening; Base element for BCC Cr-base alloys, expensive and difficult in manufacturing; Improve oxidation/corrosion resistance, and mechanical strength through M7C3,M23C6 formation and solid solution strengthening. The major function of these elements is to improve mechanical strength of base alloys through carbide formation. Besides these elements are usually sitting on substitutional positions for solution strengthening. Increase mechanical strength through carbides (MC, M23C6, M6C) formation and solid solution strengthening; Improve pitting corrosion resistance. Increase mechanical strength through carbides (MC, M23C6, M6C) formation and solid solution strengthening. Improve mechanical strength through formation of carbide (MC) and precipitates Ni3(Al,Ti). Improve mechanical strength through carbide (MC) formation; precipitation strengthening and solution hardening. Improve mechanical strength through carbides (MC) formation and solution hardening; Modify oxidation resistance. These elements are sitting on interstitial positions in the lattice of matrix, and may form carbides on grain boundaries. They are austenite stabilizer and thus ought to be controlled to limited level in ferritic structure. Improve mechanical strength through carbide (Fe3C, M7C3, M(CN)) formation and solution strengthening; Causes grain boundary segregation by forming carbides. Austenite former and closely controlled in ferritic structures. Improve mechanical strength through formation of M(C,N) carbonitrides and solution strengthening; Austenite stabilizer and closely controlled in ferritic structures for lower TEC.

Effects on properties relevant to SOFC applications

Base-elements Ni
Base For NiBSA Base For FeBSA 0-20 0-22 0-20

Fe

0-20

Base

0-5.0

Co

Base

Cr

5-25

19-30

5-28

Base

Carbide formers or strengthening elements Mo W Ti Nb Nb,Ta

0-12 0-12 0-6.0 0-5.0 0-12.0 0-11 0-11 0-4.0 0-4.0 0-9.0 0-12 0-12 0-6.0 0-6.0 0-12.0 0-10 0-10 0-0.5

Interstitial elements C
<0.20 Ni-B <0.78 Fe-B 0-1.0 <0.02 FSS <0.78 ASS <1.00

22

Continue Table III. Composition range Alloying

Elements
Ni/FeBSA CoBSA SS CrBSA The major function of these elements is to form a oxide scale on the alloy surface to protect surface. 19-30 5-28 Base Form semiconductive Cr2O3 scale to provide oxidation and corrosion resistance; For optimum performance, the Cr content should not be less than 18% in Ni-/FeSA and SS; Increase mechanical strength through M7C3,M23C6 formation and solid solution strengthening. Form an insulate Al2O3 scale to give a much better oxidation Cr2O3 scale; For continuous and adherent scale, Al should be over 3%, but usually less than 5%; Form precipitates Ni3(Al,Ti) for hardening. Form an insulate SiO2 scale for oxidation resistance; Adherence of the scale is weaker than Cr2O3 and Al2O3 scales; Be susceptible to internal oxidation. The so-called reactive elements, usually rare earth elements plus Y, can dramatically improve oxidation, corrosion, and scaling resistance. Besides their oxide forms can also help improve high temperature mechanical strength. Dramatically improve oxidation and hot corrosion resistance; Decrease resistance loss at the interface. Increase oxidation resistance significantly; Improve mechanical strength through oxide dispersion. Raise price if mechanical alloying is used to disperse oxides.

Effects on properties relevant to SOFC applications

Scale formers Cr
5-25

Al

0-6.0

0-4.5

0-6.0

Si

0-5.0

0-6.0

0-2.0

0-2.0

Reactive elements Re Re2O3

0-0.200 0-2.0 0-0.200 0-2.0 0-0.200 0-3.0 0-0.200 0-2.0

Others Mn
<1.0 for NiBSA 0~5.0 for FeBSA 0-2.0 0-6.0 0-2.0 Used to replace Ni and thus cut the price, typically 2 Mn for 1 Ni.

P S

Usually be considered detrimental and closely controlled; But promote general precipitation of carbides in Fe-base alloys and improve machinability. Usually be considered detrimental and closely controlled; But promote machinability.

Re: rare earth elements, such as Y, La, Ce. NiBSA: nickel based superalloy; FeBSA: iron based superalloy; CoBSA: co-base superalloys. CrBA: Cr-base alloys. SS: stainless steels; FSS: ferritic stainless steels; ASS: austenitic stainless steels.

23

V.

Conclusions

Alloys showing high temperature oxidation resistance can be considered as potential interconnection / bipolar separator materials for SOFC application. The high temperature alloys of interest include Ni-, Fe-, Co-base superalloys, Cr-base alloys and stainless steels. The oxidation and corrosion resistance of selected alloy systems can be improved through the addition of alloying elements, such as Cr and Al, which can form an adherent scale on the alloy surface to provide the necessary protection of the metallic substrate and long term structural stability of the component. To form a continuous and adherent scale for long term oxidation and corrosion resistance, the Cr concentration in a high temperature alloy should not be less than about 18% in Ni- and Fe-base alloys (including stainless steels), and 22% for Co-base alloys. If an appropriate amount of Al (1~3.0 wt%) is added, the recommended minimum Cr content could be lower, but still must exceed about 15% in order to have enough internal oxidation resistance. As the Al concentration increases over 3% (but usually less than 5%), a continuous and adherent alumina layer will become the dominant component in the scale on the alloy surface. These alloys are classified as alumina formers, which demonstrate much more improved oxidation and scaling resistance than chromium formers. The insulating nature of the alumina scale may however prevent any application in SOFC, unless the stack is designed in such a way that the insulating alumina scale can be excluded from the electrical path. In terms of TEC, ferritic stainless and Cr-base alloys offer better TEC match with other SOFC components than Ni-, Fe-, and Co-base superalloys and austenitic stainless steels. The high price and difficulty in fabrication of Cr- and Co-base alloys make them less favorable for intricate shape formation and large volume commercial application in SOFC power generation systems. Among the high temperature alloys, the stainless steels offer the lowest cost and reasonable manufacturability. A disadvantage of the ferritic stainless steels however is their lower mechanical strength, especially at the high temperatures required for operation of SOFC. Addition of more Cr and other alloying elements could lead to improved strength and corrosion resistance, but could also cause the sigma phase formation at the SOFC operating temperature around 800oC, resulting in embrittlement and possible TEC mismatch. Though numerous alloy compositions are available for consideration, there are few if any compositions which will satisfy the functional requirements of the interconnect in SOFC. One of the biggest concern remains that the currently available alloys may not offer high enough oxidation resistance and electronic conductivity of the oxide scale. As a result, it is likely that new alloy compositions and/or protective surface modifications or coatings will be required. To improve the oxidation resistance and control the electrical resistance of the oxide scale at an acceptable level in the long run, one effective approach may be to add reactive elements, such as Y, Ce, La or their oxide forms into the high temperature alloys. These elements can be added as a trace amount (0~0.1%) to the alloys, but significantly modify the growth behavior and consequently improve oxidation and scaling resistance, as well as the scale resistance. Another possible solution is to apply a dense, electrically conductive coating to inhibit the growth of chromia scale and decrease the resistance of the scale. Considerable development work 24

will be required in order to produce a completely satisfactory interconnect material for SOFCs operating at intermediate temperatures.

VI. Acknowledgement
This work was funded by the U.S. Department of Energys National Energy Technology Laboratory (NETL) under the Core Technology Program (CTP) of the SolidState Energy Conversion Alliance (SECA).

25

References
1. Gerald E. Wasielewski and Robert A. Rapp, High Temperature Oxidation, in The Superalloys, edited by C.S. Sims and W. Hagel, John Wiley & Sons, Inc., pp 287-317, 1972. 2. G.S. Giggins and F.S. Pettit, Trans. Met. Soc.AIME, 245, 2495-2514 (1969). 3. M.J. Donachie, Jr., Introduction of Superalloys, in Superalloy Source Book, compiled by M.J. Donachie, Jr., American Society of Metals, Metal Park, Ohio, pp 10, 1984. 4. C.T. Sims, P.A. Bergman, and A.M. Beltran, ASME Preprint 69-GT16, March, 1969. 5. P. Kofstad and Z. Hed, J. Electrochem. Soc., 116, 224-229 (1969). 6. P. Kofstad and Z. Hed, J. Electrochem. Soc., 116, 229-234 (1969). 7. P. Kofstad and Z. Hed, J. Electrochem. Soc., 116, 1542-1550 (1969). 8. W.J. Quadakkers, H. Greiner, M. Hansel, A. Pattanaik, A.S. Khanna, and W. Mallener, Solid State Ionics, 91, 55-67(1996). 9. Metals Handbook, Vol.3: Properties and selection: Stainless steels, Tool materials and Special Purpose Materials, American Society of Metals, Metals Park, OH. 10. Alloy Data: Carpenter 21Cr-6Ni-9Mn, Carpenter Steel Division, Carpenter Technology Corporation, 2000. 11. R.A. Lula, Stainless Steels, American Society for Metals, Metals Park, Ohio, 1986. 12. N. Birks and H. Rickert, J. Inst. Met., 91, 308 (1961). 13. O.F. Devereux, Topics in Metallurgical Thermodynamics, Robert E. Krieger Publishing Company, Malabar, Florida, pp.392-44, 1998. 14. K. Huang, P.Y. Hou, J.B. Goodenough, Solid State Ionics, 129, 237-25 ( 2000). 15. P. Kofstad, High Temperature Corrosion, Elsevier Applied Science Publishers Ltd., London, 1988. 16. P. Kofstad, Nonstoichiometry, Diffusion and Electrical Conductivity in Binary Metal Oxides, Wiley-Interscience, New York, 1972. 17. A. Hol and P. Kofstad, Solid State Ionics, 69, 127-, (1994). 18. T. Brylewski, M. Nanko, T. Maruyama and K. Przybylski, Solid State Ionics, 143, 131-150, 2001. 19. D. M. England and A. V. Virkar, Solid State Ionics, 146(9), 3196-3202 (1999) 20. S. Linderoth, P.V. Hendriksen and M. Mogensen, J. Mater. Sci., 31, 5077-5082 (1996). 21. P. Kofstad and R. Bredesen, Solid State Ionics, 52, 69-75 (1992). 22. S.P.S. Badwal, R. Deller, K. Foger, Y. Ramprakash and J.P. Zhang, Solid State Ionics, 99, 297-310 (1997). 26

23. C. Wagner, Diffusion and High Temperature Oxidation of Metals, in: Atom Movements, ASM, Cleveland, 1951. 24. K. Hauffe, Oxidation of Metals, Plenum Press, New York, 1965. 25. Z.G. Yang, K.S. Weil, and D.M. Paxton, private communication. 26. T. Malkow, Untersuchungen zum Langzeitverhalten von metallischen interkonnektorwerkstoffen der Hochtemperatur-Brennstoffzelle (SOFC) im Hinblick auf die Kompatibilitat mit cathodenseitigen Kontaktschichten, Dissertation, Berichte des Forschungszentrums Julich, 2000. 27. J.O. Anderson and B. Sundman, Calphad, 11, 83-92 (1987). 28. T. Kadowaki, T. Shiomitsu, E. Matsuda, H. Nakagawa and H. Tsuneizumi, Solid State Ionics, 67, 65-69 (1993). 29. W.J. Quadakkers, H. Greiner, M. Hansel, A. Pattanaik, A.S. Khanna and W. Mallenr, Solid State Ionics, 91, 55-67 (1996). 30. E. Batawi, A. Plas, W. Strab, K. Honegger, and R. Diethelm, in Solid Oxide Fuel Cells VI, edited by S.C. Singhal and D. Dokiya, PV99-19, The Electrochemical Society Proceedings Series, Pennington, NJ, P.767, 1999. 31. S. Linderoth, Surface and Coating tech., 80, 185-189 (1996). 32. C. Gindorf, L. Singheiser and K. Hilpert, Reihe Energietechnik, 15 (2), 723-726 (2000). 33. K. Hilpert, D. Das, M. Miller, D.H. Peck and R. Weib, J. Electrochem. Soc., 143 (11), 3642-3647. 34. Y. Matsuzaki and I. Yasuda, J. Electrochem. Soc., 148 (2) A126-131 (2001).

27

Appendix A Compositions of High Temperature Alloys

Ni-Cr or Ni-Cr-Fe Base Alloys Alloysa Ni
AF2-IDA Alloy 713Cc Alloy 713LCc Astroloyd B-1910 GMR-235c GMR-235Dc Hastelloy C Hastelloy C-4 Hastelloy C-22 Hastelloy C-276 Hastelloy C-2000 Hastelloy D-205 TM Bal Bal Bal Bal Bal Bal Bal 56.0 Bal 51.6 Bal Bal Bal

Nominal composition, wt% Cr

12.0 12.5 12.00 15.0 10.0 15.5 15.5 16.5 16.0 21.5 15.5 23 20

UNS

Fe
0.5b ----10 4.5 6.0 3.0 5.5 5.0 -6.0
b

Co
10.0 --15 10.0 ---2.0 2.5 2.5 --b b

C
0.35 0.12 0.05 0.06 0.10 0.15 0.15 0.15b 0.015 0.01 0.02 0.01 0.03
b b

Mn Si
0.1b ----0.25b 0.10b -1.0 1.0 1.0 --b b

Mo W
3.0b 4.2 4.5 525 3.0 5.25 5.0 17.0
b

Cb Ti
-2.0 2.0 ----------3.0 0.8 0.6 3.5 1.0 2.0 2.5 -------

Al
4.6 6.1 5.9 4.4 6.0 3.0 3.5 -------

B
0.015 0.012 0.01 0.03 0.015 0.06 0.05 -------

Zr
0.10 0.10 0.10 -0.1 ---------

Others
1.5Ta ---7.0Ta ----0.3V 0.35V
b

0.1b ----0.60b 0.30b -0.08 0.1 0.08 0.08 5.0

b

6.0 ------4.5 -4.0 4.0 ---

N13017

N10002 N06455 N06022 N10276

15.5 13.5 16.0 16.0 2.5

1.6 Cu 2.0Cu

28

Alloys

Nominal composition, wt% Ni Cr

22.0 22.0 30.0 20.0 7.0 15.5 5.0 22.0 22.0 20 22.0 17.6 8.0 19 28 16 22.0

UNS

Fe
19.5 19.5 1.5 17.5 5.0b 3.0b 5.5 18.5 20
b

Co
2.5b 5.0
b

C
0.05b 0.015 0.03 0.02 0.06 0.02b 0.12 0.10
b b

Mn Si
1.5 0.80 1.5 1.0 -0.50 -1.0
b b

Mo W
6.5 7.0 5.5 9.0 16.0 14.5 24.5
b

Cb Ti
--1.5 0.5 ----0.7b -1.8 -0.5b ----0.4 ---3.1 ----

Al
---0.4 -0.2 ----0.3 4.5 0.5 1.5 -4.0 --

B
----0.009 ----0.005 0.01 0.006 0.006 ----

Zr
----------

Others
2.0Cu, 2.0Cb+Ta 1.9Cu, 0.30Cb+Ta -0.5Cu -0.02La 0.6V --0.5Cu

Hastelloy G Hastelloy G-3 Hastelloy G-30 Hastelloy G 50 Hastelloy N Hastelloy S Hastelloy W Hastelloy X Hastelloy HX Haynes 75 Haynes 230 Haynes 214 Haynes 242 Haynes R-41 Haynes HR-160 HAD 8077 Illium Gc
TM

Bal Bal Bal Bal. 72.0 Bal 61.0 Bal Bal Bal Bal Bal Bal Bal Bal Bal Bal

1.0b 0.40 1.0 1.0 -0.40 -1.0 1.0 1.0 0.4 0.2 0.8 0.5
b

1.0b 1.5
b

N06007 N06985 N06030

5.0 2.5 -2.0b 2.5 1.5 2.5 5-5.0 -2.5 11 29 --b b

2.5 1.0 -1.0b -0.6

b

N10003 N06635 N10004 N06002

9.0 10.0 -2.0 -25 10 --6

0.15

1.0 1.0 0.5 0.5 0.8 0.1 ---b

1.0 --

----------

5.0 3.0 3.0 2 5

b

0.11 0.10 0.05 0.03 0.09 0.05 -0.20

14.0 -------

-0.1 ------

0.02La 0.01Y 0.5 Cu ---6Cu

N06230 N07214 -N07041 N12160

2.0 -5

2.75 ---

--

29

Alloysa Ni
Illium 98c Illium Bc Illium W IN-100 In-102 IN-162c IN-587 IN-597 IN-643c IN-657
c c

Nominal composition, wt% Cr

28.0 28.0 16.0 10.0 15.0 10.0 28 24.5 25.0 50 9.5 16.0 12.7 20.0 22.5 15.0 20.0 30.0 0.5b 0.5b --0.5 --1.0
b

UNS

Fe
--6.0 -7.0 0.5b --3.0

Co
---1.5 --20.0 20.0 12.0

C
0.05 0.05 0.08 0.18 0.06 0.12 0.05 0.05 0.50

Mn Si
----0.75
b

Mo W
8 8 17 3.0
b

Cb Ti
----2.9 1.0 --2.0 1.0 ---4.7 0.5 1.0 2.3 3.0 0.25

Al
---5.5 0.5 6.5 1.2 1.5 --

B
---0.014 0.005 0.020 0.003 0.012 --

Zr
---0.06 0.03 0.10 0.05 0.05 0.25

Others
5Cu 5Cu -1.0V 0.02Mg 2.0Ta -0.02Mg --

Bal Bal Bal Bal Bal Bal 47.2 48.4 Bal 50 Bal Bal Bal 74.6 Bal 68.5 78.5 Bal

-3.5 --0.4

--4 -3.0 2.0 --9.0

-----

2.9 4.0 -1.5 0.5

0.10b ----

0.20b ----

IN-731c IN-738c IN-792c IN-853 IN-939 IN MA-6000E Inconel MA 754 Inconel MA 758

10 8.5 9.0 -19.0 ----

0.18 0.17 0.21 0.05 0.15 0.05 0.05 0.05

0.2b 0.2b --0.2 ---b

0.2b 0.3b --0.2 ---b

2.5 1.75 2.0 --2.0 ---

-2.6 3.9 -2.2 4.0 ---

-0.9 -------

4.65 3.4 4.2 2.5 3.7 2.5 0.5 0.5

5.5 3.4 3.2 1.5 2.0 4.5 0.3 0.3

0.015 0.01 0.02 0.007 0.014 0.01 ---

0.06 0.10 0.10 0.07 0.14 0.15 ---

0.95V 1.75Ta 3.9Ta 1.3 Y2O3 1.1Nb, 1.4Ta 1.1 Y2O3, 2.0Ta 0.6 Y2O3 0.6 Y2O3

N07754 --

30

Alloys

Nominal composition, wt% Ni Cr

15.5 23.0 22.0 21.0 21.5 46.0 21.0 29.0 16.0 18.5 21.0 15.5 3.0 15.5 19.0 9.0 8.25 15.5

UNS

Fe
8.0 14.1 1.5 4.0 2.5 -1.0 9.0 40.0 18.5 ~12.0 7.0 25.5 7.0 -0.15 0.5b 1.0b
b

Co
--12.5 2.5 ---------Rem -10 10 10.0 10
b

C
0.08 0.05 0.1 0.015 0.05 0.05 0.01 0.02 0.03 0.04 0.03b 0.05 0.10b 0.04 0.15 0.15 0.15 0.15
b b

Mn Si
0.5 0.5 0.5 0.5 0.2 -0.75 0.2 0.2 0.2 0.35b 0.5 -0.5 0.5
b b b

Mo W
--9.0
b

Cb Ti
----3.6 ---2.9 5.1 -1.0 -1.0 ---1.75 --0.3 -0.2 0.4 0.02 -1.8 0.9 1.4 2.3 0.2 2.5 2.6 1.5 1.0 1.75

Al
-1.4 1.2 -0.2 ---0.2 0.5 0.35b 1.2 5.4 0.7 1.0 5.5 5.5 4.25

B
------------0.008 -0.005 0.015 0.015 0.015

Zr
---------------0.05 0.05 0.05

Others
0.2Cu 0.2Cu 0.2Cu 0.35 V ---0.2Cu 0.2Cu 0.2Cu -0.2Cu 3.0Nb, 0.50bCu 0.2Cu -1.5Ta, 0.1Cu 1.5Hf, 3.0Ta -b

Inconel 600 Inconel 601 Inconel 617 Inconel 622 Inconel 625 Inconel 671 Inconel 686 Inconel 690 Inconel 706 Inconel 718 Inconel 725 Inconel 751 Inconel 783 Inconel X-750 M-252, J1500 (Carpenter) MAR-M246c MAR-M247 MAR-M421c
TM

76.0 60.5 52.0 Bal 61.0 53.5 Bal 61.0 52.5 73.0 57.0 Bal 28.0 72.5 Bal Bal 59.0 Bal

0.2 0.2 0.5 0.08 0.2 -0.08 0.2 0.2 0.2 0.20b 0.2 0.50b 0.2 0.5
b b

------3.7 --------10.0 10.0 3.5

N06601 N06601 N06617 N06022 N06625 -N06686 N06690 N09706 N07718 N07725 --N07754

13.5 9.0 -16.0 --3.0 8.3 ---10 2.5 0.7 1.75

0.10 -0.20b

0.05 -0.20b

31

Alloys

Nominal composition, wt% Ni Cr

15.5 12.0 14.6 27.0 25.0 12.0 20.0 25.0 19.5 19.5 30 19.5 19.5 11.0 24.2 14.8 15.0 20.0 13.5 -5.0b 2.0b -1.0 1.0
b

UNS

Fe
---18.5 9.5 ---3.0b --

Co
20 -15.2 --10 --2.0b 1.1

C
0.15 0.05 0.07 0.50 0.20 0.10 0.01 -0.1b 0.06

Mn Si
----0.1 -0.1 -1.0b 0.10 ----0.5 -0.70 -1.0b 0.70

Mo W
-4.5 4.4 -0.5 --10.0 --3.0 --6.0 -8 -----

Cb Ti
2.0 2.0 --------4.3 0.6 3.35 --4 0.4 -2.25 2.5 1.8

Al
2.8 5.9 4.3 -0.15 4 --1.4 1.3 1.0 1.4 2.0 5.0 1.4 4.7 5.0 2.6 (+Ti) 0.2

B
0.015 0.010 0.015 -2.1 0.050 --0.008b --

Zr
0.05 0.10 0.03 --0.05 --0.15b --

Others
2.0Ta 1.3Hf 1.3Hf ----0.03Ce ---

MAR-M432c MM-004c MM-008c NA-224 Nicrofer 6025HT-602CA Nicrotungc Nimonic 75 Nimonic 86 Nimonic 80 Nimonic 80A Nimanic 81 Nimonic 90 Nimonic 95 Nimonic 100 Nimonic 101 Nimonic 105 Nimonic 115 Nimonic 263 RollsRoyce263 Nimonic 901

Bal Bal Bal 48.0 Bal Bal 78.8 65.0 Bal. 74.7 Bal 57.4 53.5 56.0 Bal Bal Bal Bal 42.7

N06025 N06075 --

N07080

18.0 18.0 20.0 19.7 20.0 14.0 20.0 --

0.07 0.15b 0.30b 0.1b 0.12 0.16 0.06 0.05

b

0.50 --1.0b 1.0 1.0

b

0.70 --1.0b 1.0 1.0

b

--5.0 1.5 5.0 4.0 5.9 6.2

---------

---------

2.4 2.9 1.5 3.0 -4.0 2.2 2.5

-+ + 0.012 0.007 0.002 0.005 --

-+ + 0.05 0.15 0.15 --b

---0.5bCu 0.2 Cu 0.2 Cu 0.2bCu -b b

N07090

---N07263 N09901

07b 34

06b 0.4

0.4b 0.4

32

Alloys

Nominal composition, wt% Ni Cr

18.0 16.0 18.0 21.5 25.0 19.0 15.0 20.0 15.0 11.0 13.0 10.3 19.0 19.0 17.0 15.0

UNS

Fe
33.5 -1.0b 18.5 18 -1.0 -1.0b 0.5b --0.5b -17.5 0.5
b b

Co
1.0 2.0b 14.0 1.50 3.0 11 18.5 -26 14.5 -10.0 18.0 12.0 1.0b 18.5

C
0.05 0.06 0.07b 0.75 0.05 0.09 0.15 -0.08 0.07 0.09 0.11 0.08 0.05 0.04 0.07
b

Mn Si
-0.2b 0.5b 1.00 1.5 ---0.3b 0.3b ----0.2b 0.2
b b

Mo W
-3.3 7.0
b

Cb Ti
---------0.5 1.5 1.5 --6.0 -2.35 1.2 2.3 --3.1 3.5 -2.4 2.5 0.6 1.0 3.0 3.0 1.1 3.5

Al
0.85 1.2 2.1 --1.5 4.25 -4.4 5.4 6.0 6.3 3.0 2.0 0.6 4.4

B
-0.005 0.005b --0.010 0.05 -0.015 0.015 0.07 0.03 0.007 0.005 0.005 0.025
b b

Zr
-0.03 0.06b -------0.07 0.10 -----

Others
-0.5bCu 0.2bCu 0.04P 0.03Sb ---2.0ThO2 --------b

Nimonic PE.11 Nimonic PE 16 Nimonic PK 33 Pyromet 680 RA-333 Rene 41 Rene 77 TDNiC SEL SEL-15 TRW 1800
c d

39.0 43.5 Bal Bal Bal Bal Bal 78.0 Bal Bal Bal Bal Bal Bal Bal Bal

-0.5b 0.5b 1.00

---0.60 3.0 ----1.5 9.0 9.0 -1.0 3.0 --

--N06002

9.00 3.0 10 5.2 -4.5 6.5 --4 6 3.1 5.0

1.25 ---0.5b 0.5b ----0.2b --

N07041 --

TRW 1900c Udimet 500 Udimet 520 Udimet 630 Udimet 700

N07500

--

33

Alloys

Nominal composition, wt% Ni Cr

18.0 18.0 16.25 12.0 19.5 19.5

UNS

Fe
0.5b -9.5 0.5b 2.0b 2.0b

Co
14.7 14.7 7.2 10.0 13.5 13.5

C
0.07 0.035 0.24 0.16 0.07 0.07

Mn Si
-0.1
b

Mo W
3.0 3.0 1.6 3.0 4.3 4.3 1.5 1.25 8.4 6.0 ---

Cb Ti
------5.0 5.0 3.2 3.0 3.0 3.0

Al
2.5 2.50 1.9 4.6 1.4 1.4

B
0.02 0.033 0.008 0.015 0.006 0.006

Zr
-0.030 0.06 0.10 0.09 0.07

Others
--.03Sb, 0.1Cub -.02Sb, 0.1Cub

Udimet 710 Udimet 720 Unitemp 1753 Unitemp AF2-1DA Waspaloy Ae Waspaloy Be

Bal Bal Bal 59.0 Bal Bal

0.2b -0.10 -0.5b 0.75b

---

0.05 -0.5b 0.75b

N07001
--

34

Notes: a. b. c. d.

Some superalloys such as Inconel 718, Rene 41, Udimet 500, and others are made by more than one manufacturer; Maximum composition; Cast alloy. Compositions of Astroloy, Rene 77, and Udimet 700 are very similar. Certain elements are controlled to prevent sigma phase formation. e. Waspaloy A has a higher solution temperature and longer time at stabilization than Waspaloy B. 1) Many of the alloy designations are registered trademarks of producer companies. For example, Hastelloy, Haynes, and Multimet are registered trademarks of Cabot Co., and Incoloy and Inconel are trade marks of Huntington Alloys Co. 2) The Unified Numbering System (UNS) is being developed jointly by the U.S. Society of Automotive Engineers (SAE) and the American Society of Testing and Materials (ASTM). Each UNS number consists of a single letter prefix followed by five digits. The interested high-temperature alloys appearing here fall into four different UNS material groups and may have prefixes of K, N, R, and S. The prefixes K, N, R and S represent the following UNS number series: Kxxxxx: miscellaneous steels and ferrous metals; Nxxxxx: nickel and nickel alloy; Rxxxxx: reactive and refractory metals and alloys; Sxxxxx: heat and corrosion resistant (stainless) steels.

Note:

35

Fe-Ni-Cr Base Alloys Alloys

a

Nominal composition, wt% Ni Cr

20.0 13 22 20 20 23 15 13.5 25.5 28 27 20 27 15.0 19.5

UNS

Fe
Bal Bal Bal Bal Bal Bal rem Bal Bal Bal Bal Bal Bal Bal Bal

Co
-----5.0 --3.25 -7 -----

C
0.05 0.05 1.05 1.00 0.70 0.75 0.05 0.04 0.50 0.20 0.08 -0.03b 0.08 0.08
b

Mn
1.40 0.1 5.00 5.00 5.00 5.00 0.75b 0.9 0.80b --2.0
b

Si
0.40 0.1 0.50 0.50 0.50 0.50 0.75b 0.8 1.0 ---1.0b 1.0
b

Mo
2.25 5.5 1.0 2.0 1.0 1.0 4.0 2.75 3.25 2.0 2.0 2.5 3.5 1.25 6.5

W
--1.0 2.0 1.0 1.0 4.0 -3.25 -------

Cb
0.15 0.6 1.0 2.0 2.0 2.0 ----------

Ti
-2.5 ----3.0 1.75 -----2.20 --

Al
-1.5 ----1.0 0.10 ---0.07b -0.35 -b

B
-0.01 0.003 0.003 0.003 0.003 0.01 ------0.005 --

Zr
----------------

Others
---0.20N 0.20N 0.25N ---3 Cu -3.5Cu 1.0Cu 0.3bV 1.0Cu

Armco 20-45-5 CG-27 CRM 6Dc CRM 15D

c

45.0 38 5.0 5.0 5.0 5.0 45 26 45.5 8 5 35.0 31.5 25.5 35.5

CRM 17Dc CRM 18D D-979 Discaloy Duraloy HOM-3c Illium Pc Illium PD
c c

---

Incoloy 020 Incoloy 028 Incology A-286 Incology 330

2.5b -2.0
b

S66286

0.5

36

Alloys

Nominal composition, wt% Ni Cr

22.0 21 20.5 21 27.0 21.5 20.0 22.5 21.0 18.0
b

UNS

Fe
Bal 46 44.5 46 Bal 30 60.0 Bal 28.0 -Bal Bal Bal Bal Bal Bal Bal Bal Bal

Co
18.0 ---------0.30 20 4.0 -20 ----b

C
0.10 0.08 0.05 0.4 0.08 0.03 -0.08b 0.01 0.10b 0.10
b

Mn
1.0 0.8 0.8 0.8 1.50 0.5 -1.0b -1.2 0.30 1.5 0.25 0.2
b b b

Si
0.4 0.5 0.5 .4 1.0 0.2 -0.8 -2.3 -0.5 0.10 0.2
b b

Mo
3.0 ----3.0 -4.4 3.0 --3.0 6.0 2.0 4.0 -1.25 1.5 6.0

W
2.5 ----------2.5 --4.0 -----

Cb
-----------1.0 (+Ta) -1.1 4.0 0.50 ----

Ti
-0.4 1.1 -0.40 0.9 -0.7 2.1 0.2 0.5 -3.0 2.5 -4.0 3.0 2.85 -b

Al
0.2 0.4 --0.4 0.1 --0.3 -4.5 -1.0 1.5 -0.15 0.25 0.20 --

B
------------0.01 0.005 -0.06 0.01 0.08 --

Zr
0.02 --------------0.05 ----

Others
0.6Ta, 0.02La 0.4 Cu 0.2 Cu 0.4 Cu 0.75 Cu 2.2 Cu ---0.50 Cu 0.5Y2O3 0.15 N, 0.50 Cub -0.015P 0.015Sb --0.5 Vb -0.15 N
b b b

Incoloy 556 Incoloy 800 Incoloy 801 Incoloy 802 Incoloy 803 Incoloy 825 Incoloy 840 Incoloy 864 Incoloy 925 Incoloy DS Incoloy MA 956 N-155, Multimet alloy Pyromet 860 (carpenter) Pyromet 31 (carpenter) S-590 Unitemp 212 Pyromet V-57 W-545 16-25-6

20.0 32.5 32 32.5 34.5 42 20.0 34.0 44.0 38.0 0.50 20 44 55.5 20 25.0 27 26 25

R30556 N08800 N08801 N08802 -N08825 -S35135 N09925

20 21 13 22.7 20.5 16.0 14.8 13.5 16

0.10 0.05 0.04 0.43 0.08 0.08b 0.08b 0.08b

R30155 -N07031

1.25 0.05 0.35b 1.50 1.35

0.40 0.15 0.75b 0.40 0.70

--

37

Alloys

Nominal composition, wt% Ni Cr

16.0 19 19 23.75 24.0 20.0 21 25

UNS

Fe
Bal Bal Bal Bal Bal Bal. Bal Bal

Co
-----2.00b --

C
0.06 0.30 0.30 0.03 0.03 0.02b 0.08 0.05

Mn
0.75 1.10 1.00 1.0 1.0 0.5b ---

Si
0.50 0.60 0.55 0.5 0.5 6.5 1.7 --

Mo
2.50 1.25 1.50 4.25 5.85 ----

W
-1.20 1.20 ------

Cb
-0.40 -------

Ti
0.3 0.30 0.55 ------

Al
---------

B
---------

Zr
---------

Others
3.5Cu --0.5~1.5 Cu 20~4.0 Cu 2.0Cu 0.04Ce 0.17N 0.7Nb 0.2N

17-14CuMo 19-9DL 19-9DX 20Mo-4 20Mo-6 25-6Mo Aktiebolag 253 MA

25.0 9.0 9.0 37.5 35.1 25.0 11 37

K63198 K63199 N08024 N08026 N08926

Haynes
HR-120

N08120

a. Some alloys are made by more than one manufacturer b. Maximum composition c. Cast alloy.

38

Standard Stainless Steels Alloys

201 202 301 302 303 304 305 308 309 310 314 316 317
a

Nominal composition, wt% S Ti Cu N

-0.06 0.045b 0.045 0.20 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.03 0.03b 0.03 0.15b 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 -------------------------0.25 0.25 0.10b -----------

Ni Cr Fe Mo C Mn Si Al P Austenitic types (Cr-Mn-Ni types-200 Series, and Cr-Ni-300 Series)

4.5 5.0 7.0 9.0 9.0 9.25 12.75 13.5 13.5 20.5 20.5 12.0 13.5 17.0 18.0 17.0 18.0 18.0 18.0 18.0 20.0 23.0 25.0 24.5 17.0 19.0 Bal Bal Bal Bal Bal Bal Bal Bal Bal Bal Bal Bal Bal ----0.6 -----2.50 -3.5 0.15 0.15 0.15b 0.15 0.15 0.08 0.12 0.08 0.20 0.25 0.25 0.08 0.08 6.5 8.75 2.0b 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 1.00 1.00 0.75 1.00 1.00 1.00 1.00 1.00 1.00 1.50 2.25 1.00 1.00 --------------

Others

UNS
S20100 S20200 S30100 S30200 S30300 S30400 S30500 S30800 S30900 S31000 S31400 S31600 S31700

39

Cont. Standard Stainless Steels Alloys

321 329 330 334 347 348
a

Nominal composition, wt% S

0.03 0.03 0.03 0.015 0.03 0.03 0.04 0.045 0.03 0.03 0.03 0.03 0.03 0.03 0.03

Ni Cr Fe Mo C Mn Si Al P Austenitic types (Cr-Mn-Ni types-200 Series, and Cr-Ni-300 Series)

10.5 4.5 35.5 19.5 11.0 11.0 18.0 27.5 18.5 19.5 18.0 18.0 Bal Bal Bal Bal Bal Bal -1.5 ----0.08 0.10 0.08 0.03 0.08 0.08 0.08 0.08 0.12 0.12 0.12 0.12 0.20 0.20 0.20 2.0 2.0 2.0 1.0 2.0 2.0 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.50 1.00 1.00 1.25 0.75 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 ------0.20 --------0.045 0.045 0.04 0.02 0.045 0.045 0.04 0.045 0.03 0.03 0.04 0.04 0.04 0.04 0.04

Ti
0.50 -----0.5 ---------

Cu
-----0.2 -------1.1 --

Others

UNS
S32100 S32900 S33000 S33400 S34700

0.8 Nb+Ta

S34800 S40500 S40900 S42900 S43000 S43400

Ferritic types ( non-hardenable) -13.0 Bal -405 409 429 430 434 436 442 443 446 --------11 15 17 17 17 20.5 20.5 25 Bal Bal Bal Bal Bal Bal Bal Bal ---1.0 1.0 ----

0.6 Nb+Ta

S43600 S44200 S44300

0.25

S44600

40

I.
410 420 440A 440B 440C 504

Martensitic types (hardenable)

------12.0 13.0 17.0 17.0 17.0 9.0 Bal Bal Bal Bal Bal Bal --0.75 0.75 0.75 1.0 0.15 0.15 0.68 0.85 1.10 0.15 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 ------0.04 0.04 0.04 0.04 0.04 0.04 0.03 0.03 0.03 0.03 0.03 0.04 -------------

S41000 S42000 S44002

S44004

II.
630 633

Precipitation hardening (Typically Cr% <18.0)

4.0 4.5 16.3 16.5 Bal Bal -2.9 0.07b 0.09 1.0b 1.0b --0.04b 0.04 0.03b 0.03 --4.0 --0.10 0.30 Cb+Ta S17400 0.85 0.5 0

Note: Some austenitic stainless steels are already listed in previous Fe-Ni-Cr Tables. Included here are ferritic stainless steels and some austenitic compositions.

41

Nonstandard Stainless Steels Alloysa Ni

308L 309S 332 20Cb-3 Al-6X AL 30 AL 33 AL 40 or AL219 AL 50 (XM-19) (22-13-5) Carpenter 21Cr-6Ni-9Mn Carpenter 11.0 13.3 32.0 35.0 24.5 2.2 3.0 6.0 12.5 6.50 13.0

Nominal composition, wt% Cr

20.0 23.0 21.5 20.0 21.0 16.0 18.5 21.0 21.5 21 22

UNS

Fe
Bal Bal Bal Bal Bal Bal Bal Bal Bal Bal Bal

Mo
---2.5 6.5 --2.0 2.25 -2.25

C
0.03 0.08 0.04 0.07 0.03

Mn
2.00 2.00 1.00 2.00 2.00 8.0 14 9.0

Si
1.00 1.00 0.50 1.00 1.00

Al
---------

P
0.045 0.045 0.045 0.045 0.030

S
0.03 0.03 0.03 0.035 0.003

Ti
---------

Cu N
Others
---3.5 -------0.20 0.27 0.30 0.3 0.27 0.30 0.2Nb 0.2V -0.2Cb 0.2V 0.6Nb S30883 S30908 N08800 N08020 N08367 S20400 S24000 S21904 S20910 S21904 N20910

Austenitic types (Cr-Mn-Ni types-200 Series, and Cr-Ni-300 Series)

0.06 0.03b 0.06b

5.0 9.00 5.00

1.0 1.00b 1.00b

----

0.04 0.04b 0.04b

0.03 0.03b 0.03b

----

22Cr-13Ni5Mn

III. Ferritic types (non-hardenable)

AL 29-4-2
AL 29-4 AL 29-4C 2.1 0.15 0.30 29.0 29.0 29.0 Bal. Bal. Bal. 4.0 4.0 4.0 0.01 0.01 0.02 0.05 0.3 0.5 0.1 0.2 0.35 ---0.025 0.025 0.03 0.02 0.02 0.01b --0.6b ---0.02 0.6b Ti+Nb 0.015 S44800 S44700 S44735

42

Alloys

Nominal composition, wt% Fe

Bal. Bal. Bal. Bal Bal Bal Bal Bal Bal Bal Bal. Bal Bal Bal Bal Bal.

UNS

Ni Cr Ferritic types (cont.)

7-Mo Stainless (Car) Alloy 255 (AL) E-Brite 26-1 Sea-cure/Sc-1 Kanthal (APM) AL 453TM Carpenter 443 PM 2000 AL 433 TM AL 444 TM ( Alloy 18-2) Armco 18 SR AL 468
TM

Mo
2.5 3.5 1.0 3.0 ------2.10 ----1.5 --

C
0.03 0.04 0.001 0.025

Mn
2.0 1.5 0.01 1.00 --

Si
0.6 1.0 .025 0.75 -0.3 1.0b -0.39 1.00 1.0 0.55 0.34 0.55 --

Al
----6.0 0.6 -5.5 --2.0 0.03 0.05 -4.5 4.0~ 5.2

Ti
--

Cu N
-2.0 0.03 ----0.5 ------0.6 --

Others
S32950 (duplex) S32550 (duplex) S44627 S44660

5.2 5.5 0.09 2.5 -0.3 --0.25 1.00 0.25 0.22 0.30 0.23 --

29.0 25.5 26.0 26.0 22 22.0 20.5 20 20.0 18.5 18.0 18.25 18.0 18.0 16.5 15.0~ 22.0

0.35 0.20 0.01

0.04 0.02 0.04

0.03b 0.02 0.03

--0.3 --

0.03 0.2b -0.01 0.025 0.015 0.009 0.009 0.012 -0.03

0.3 1.0b -0.30 1.00 0.30 0.40 0.35 0.45 --

0.02 0.04b -0.021 0.04 -0.024 0.023 0.02 --

0.03b 0.0b -0.001 0.03 -0.001 0.002 0.001b --

0.02 ---0.4 0.4 0.10 0.29 0.40 ---

0.10b (Ce+La) 1.0Cu 0.5Y2O3

-S44300

0.019 0.035 0.25 0.016 0.014 0.013

0.54 Cb, 0.80b

S43300 S44400

0.25 Cb 0.71 Cb 0.8b Ti+Cb

S46800

AL 441 HPTM AL 439 HPTM ODM 751 Fecralloy d

S43035
0.5Y2O3 0.05~0.5% Y

43

Alloys

Nominal composition, wt% Ni Cr

12.5

UNS

Fe
Bal

Mo
--

C
0.18

Mn
1.00

Si
1.00

Al
--

P
0.04

S
0.03

Ti
--

Cu N
--

Others

IV. Martensitic types, hardenable

410Cb (XM-30)
-0.2 Nb

V.

Precipitation-hardening stainless steels

6.75 16.75 Bal -0.08 1.00 1.00 0.4 0.04 0.03 0.8 ---

Stainless W (635)

Sealing-glass or Control-expansion Alloys *

AL 430Ti AL sealmet 485 Carpenter 18 Carpenter 27
47.0 -0.5b 20.0 6.0 18.0 28.0 Bal Bal Bal Bal --0.10 0.05 0.60 0.60 0.40 0.40 --0.40 ----

R91800 ---

a. Some alloys are made by more than one manufacturer; b. Maximum composition; c. Cast alloy

d. Fecralloy is a group of alloy, in which Fe, Cr, Al and rare earth elements are major alloying elements. * For glass-to-metal sealing applications, the thermal expansion characteristics of glass and metal are closely matched and the metal must also have an oxide which fluxes at high temperature with the glass to provide a hermetic and mechanically sound joint.

44

Co Base Alloys Alloysa Ni

AiResist 13c AiResist 213 AiResist 215c Elgiloy CM-7 FSX-414c FSX-418c FSX-430c Haynes 21c Haynes 25 (WF-11, L 605) Haynes 150 Haynes 188
1.0b --15.0 15.0 10.5 10.5 10.0 3 10

Nominal composition, wt% Cr

21 19 19 20.0 20.0 29.5 29.5 29.5 27 20

UNS

Fe
2.5b --Bal -2.0b 2.0b -1 3.0b

Co
Bal Bal Bal 40.0 48.0 Bal Bal Bal 64 Bal

C
0.45 0.18 0.35 0.15 0.10 0.25 0.25 0.40 0.25 0.10

Mn
0.5b --2.0 -1.0b 1.0b --1.50

Si
-----1.0b 1.0b --0.50

Mo
---7.0 ----5 --

W
11 4.7 4.5 -15.0 7.0 7.0 7.5 -15

C b
2.0 ----------

Ti Al
----1.3 -----3.5 3.5 4.3 -0.5 ------

B
-----0.012 0.012 0.027 ---

Zr
-0.15 0.13 ----0.9 ---

Others

0.1Y 6.5Ta, 0.1Y 7.5Ta, 0.17Y 0.04Be --0.15Y 0.5Y ---

3.0b 22

28 22

20.0 3.0b

Bal Bal

0.08 0.10

0.65 1.25b

0.35 0.3

1.5b --

-14

---

---

---

---

---

-0.04La

R30188

45

Alloys

Nominal composition, wt% Ni Cr

30.0 31.0
20.0 21.5

UNS

Fe
1.0 3.0b
2.0 --

Co
61.5 59.0
46.0 Bal

C
1.0 1.6
0.2 0.85

Mn
1.4 2.0b
-0.10

Si
-2.0b
-0.20

Mo
1.5 1.50b
---

W
4.0 4.50
-10.0

C b
-----

Ti Al
--4.0 --

B
---0.005

Zr
---0.15

Others
---9.0Ta

Haynes 6B (Stellite) Haynes 6K (Stellite) J-1570 MAR-M302c MAR-M322c MAR-M509c MAR-M918 MP35N MP 159 NASA Co-W-Rec S-816 TD Co UMCo-50 ULTIMET V-36c

3.0 2.0
28.0 --

-----

R30006
R30006

-10 20 35.0 25.0 -20 20.0 -9 20 10

21.5 21.5 20 20.0 19.0 3 20 18.0 28.0 26 25 20

-1.0 0.5b -9.0 -4 -21.0 3 3 --

Bal Bal Bal 35.0 36.0 Bal Bal 60.0 49.0 54 Bal Bal

1.00 0.60 0.05 --0.40 0.38 -0.12b 0.06 0.27 0.15

0.10 0.10b 0.2b ---1.20 --0.8 1.00 1.42

0.10 0.10b 0.2b ---0.40 --0.3 0.40 0.42

---10.0 7.0 -4.0 --5.0 4.0 2.6

9.0 7.0 ---25 4.0 --2.0 2.0 10.7

------4.0 ---2.0 --

0.7 5 0.2 --3.0 1.0 -----1.0

----0.2 --------

-0.010b -----------

2.25 0.50 0.10 --1.0 -------

4.5Ta 3.5Ta 7.5Ta --2.0Re -2.0ThO2 -----

WF-31

46

Alloys
WI-52c
X-40c X-45c

Nominal composition, wt%

1.0b 10 10.5

UNS

Ni

Cr
21 25 25.5

Fe
2.0 1.5 2.0b

Co
Bal Bal Bal

C
0.45 0.50 0.25

Mn
0.50b 0.50 1.0b

0.50b 0.50 --

Si

Mo
----

W
11 7.5 7.0

Cb
2.0 ---

Ti
----

Al
----

B
--0.010

Zr
----

Others
----

a. Some alloys are made by more than one manufacturer b. Maximum composition c. Cast alloy.

47

Cr Base Alloys Alloysa Ni Cr Fe Co C

C207 CI-41 IM-15 Chrome 30 Chrome 90 Chrome 90s Duraclloy (plansee) -------Bal Bal Bal Bal Bal Bal Bal ------5.0 -------0.10 0.09 ---0.5 0.002 -----------0.5 1.0 --7.1 ------

Nominal composition, wt% Mn Si Mo W Cb Ti Al B

7.5 -------------0.2 --0.5 -0.5 ----------0.1 -----

UNS

Zr Others
0.8 ------0.15Y 0.1 (Y+La) 2.0 Ta 1.7 Ta 0.1 Y 6MgO 3MgO, 2.5V 3MgO, 2.5Ta 1.0 Y2O3, 0.006La, 0.001S, 0.0066N

a. Some alloys are made by more than one manufacturer b. Maximum composition c. Cast alloy.

48

Appendix B Selected Compositions Ni-Cr or Ni-Cr-Fe Base Alloys

Alloys
a

Nominal composition, wt% Ni Cr Fe

46.0 50 30.0 30.0 30.0 29.0 28 28 27.0 25.0 25.0 25.0 24.5 1.5 9.0 -2.0 18.5 9.5 -18 -5.0 -20.0 29 ---3.0 20.0 0.03 0.02 0.05 0.05 0.50 0.20 -0.05 0.05 1.5 0.2 ---0.1 -1.5 -1.0 0.2 -2.75 -0.5 -1.25 -5.5 ----0.5 10.0 3.0 1.5 2.5 ---6.0 --3.0 -1.5 --------1.8 -2.3 -----3.0 1.0 -0.05 ------

Characteristics,

Co
---

C
0.05

Mn Si
---

Mo W
---

Cb Ti
-1.0 -0.5 0.4

Al
--

B
--

Zr
--

Other s
--

Typical applications
For extremely corrosive environments

Inconel 671 IN-657

c

53.5 50 Bal Bal Bal 61.0 47.2 Bal 48.0 Bal 65.0 Bal 48.4

Inconel MA 758 Nimonic 81 Hastelloy G-30 Inconel 690 IN-587 Haynes HR-160 NA-224 Nicrofer 6025HT602CA Nimonic 86 RA-333 IN-597

0.3 1.0 --1.2 --0.15 --1.5

--

--

0.6 Y2O3 2.0Cu

MAed, furnace skid rails at 1260oC, fuel atomizer in diesel engine Superior corrosion resistance Resist nitric/hydrofluoric acid

--0.003 --2.1 --0.012

--0.05 -----0.05

-0.2Cu ----0.03Ce -0.02Mg

Developed for high temp. hot corrosion resistance

Excl. resist. To oxidation & carburising at high oC Combusion chamber, excep. Oxidation & scaling resistance Turbine parts, radiant tubes Stressed parts in turbines, Excl. oxidation & corrosion resistance (>900oC)

49

Alloys

Nominal composition, wt% Ni Cr Fe

24.2 23.0 23 -14.1 --

Characteristics,

Co
19.7 ---

C
0.1b 0.05 0.01b

Mn Si
1.0b 0.5 -1.0b 0.2 0.08b

Mo W
1.5 -16.0 ----

Cb Ti
---3.0 ---

Al
1.4 1.4 --

B
0.012 ---

Zr
0.05 ---

Other s
0.5bCu 0.2Cu 1.6 Cu Similar to IN 597

Typical applications
Furnace, heat treat fixtures Superior oxidation and corrosion resistance in both oxidizing and reducing environments. Developed for chemicals industries. Appls. In marine environment or less pure fuel. Combination of strength, stability, oxidation and fabric ability Aero ducks, combustors Gas turbine aircraft engine parts Resists pitting and stress-corrosion cracking Phosphoric acid service Engine sheet parts, good oxidation resistance

Nimonic 101 Inconel 601 Hastelloy C-2000 IN-939 Haynes 230 Hayness 556 Inconel 617 Hastelloy G Hastelloy G-3 Hastelloy X Hastelloy HX Pyromet 680 Hastelloy C-22 Inconel 625 Inconel 622 Inconel 686

Bal 60.5 Bal

Bal Bal 21.0 52.0 Bal Bal Bal Bal Bal 51.6 61.0 Bal Bal

22.5 22.0 22.0 22.0 22.0 22.0 22.0 22.0 21.5 21.5 21.5 21.0 21.0

0.5b 3.0 29.0 1.5 19.5 19.5 18.5 20b 18.5 5.5 2.5 4.0 1.0b

19.0 5.0 20.0 12.5 2.5b 5.0b 1.5 2.5b 1.50 2.5 -2.5b --

0.15 0.10 0.10 0.1 0.05b 0.015b 0.10 0.15b 0.75 0.01 0.05 0.015b 0.01b

0.2b 0.5 -0.5 1.5 0.80 1.0b 1.0 1.00b 1.0 0.2 0.5b 0.75b

0.2b 0.4 -0.5 1.0b 0.40 1.0b 1.0 1.00b 0.1 0.2 0.08b 0.08b

-2.0 3.0 9.0 6.5 7.0 9.0 10.0b 9.00 13.5 9.0 13.5 16.0

2.2 14.0 2.5 -1.0b 1.5b 0.6 1.0b 0.60 4.0 --3.7

----------3.6 ---

3.7 --0.3 0.7b -----0.2 -0.02

2.0 0.3 0.3 1.2 ------0.2 ---

0.014 0.005 ------------

0.14 -0.002 -----------

1.1Nb, 1.4Ta 0.02La 0.02La, 0.50Ta 0.2Cu 2.0Cu, 2.0Cb+Ta 1.9Cu, 0.30Cb+T a --0.04Pb 0.03Sb 0.3V -0.35bV --

Turbine rotors, shafts; furnaces, chemical industry Superior weldability, used as overalloy filler to improve corrosion resistance Aircraft engines/structures, chemical processing Excl. resistance to oxidizing & reducing acidic environments. Used in the most severe environments in chemical processing, food production, etc.

50

Alloys

Nominal composition, wt% Ni Cr Fe

20.0 20 20.0 20.0 20.0 20.0 20.0 20.0 20 19.5 19.5 19.5 19.5 19.5 19.5 19.0 19.0 17.5 6.0 07b --18.0 --5.0 5.0b -2.0 2.0
b

Characteristics,

Co
2.5 -20.0 --2.5b --5-18.0 18.0 13.5 13.5 2.0b 1.1

C
0.02 0.03b 0.06 0.05 0.05 0.02b -0.01 0.11 0.15b 0.07 0.07 0.07 0.1b 0.06 0.08 0.05

Mn Si
1.0 -06b --1.0b -0.1 1.0 -0.50 0.5
b

Mo W
9.0 2.5 5.9 --9.0 -----4.3
b

Cb Ti
0.5 ----0.5b -------------2.2 2.5 0.5 --0.4 0.4 2.9 2.4 3.0 3.0 2.25 2.5 3.0 3.0

Al
0.4 -2.6 (+Ti) 1.5 0.3 0.4b ---2.0 1.4 1.4 1.4 1.4 1.3 3.0 2.0

B
-0.005 0.007 -----+ -0.006 0.006 0.008b -0.007 0.005

Zr
---0.07 -----

Other s
0.5Cu 2.0Cu 0.2bCu 1.3 Y2O3 0.6 Y2O3 0.5bCu 2.0ThO2 -0.5Cu

Typical applications
For appli. In severe sour gas env. Outstanding corrosion resistance to concentrated acidic media, silica forming alloy Turbine rings, casings

Hastelloy G 50 Hastelloy D-205 TM Nimonic 263 RollsRoyce263 IN-853 Inconel MA 754 Inconel 050 TDNiC Nimonic 75 Haynes 75 Nimonic 95 Nimonic 90 Waspaloy A Waspaloy B Nimonic 80 Nimonic 80A Udimet 500 Udimet 520
d

Bal. Bal Bal 74.6 78.5 50.0 78.0 78.8 Bal 53.5 57.4 Bal Bal Bal. 74.7 Bal Bal

1.0 5.0 0.4b --1.0b -0.70 1.0 -0.70 0.5

b b

1.0 ----1.0b ----------1.0

MAed, turbine vanes Oil tubular goods, Excl. corrosion resistance in a variety of enviro.

Sheet parts in turbines, nuclear engineering. Equivalent to alloy 600, low stress elevated temperature with reasonable oxidation resistance requirement.

+ -0.09 0.07 0.15b ----

--.02S , 0.1Cub -----b

Turbine blades & discs, hot working tools Jet engine blades Jet engine discs Turbine blades, rings and discs. Turbine blades, rings and discs. Gas turbine parts/sheets/bolts Similar to Udimet 500, improved workability

0.75 1.0b 0.10 ---

0.75 1.0b 0.70 ---

4.3 --4 6

3.0b -0.5 -b

18.0 12.0

51

Alloys

Nominal composition, wt% Ni Cr Fe

19.0 19.0 18.5 18.0 18.0 18.0 18.0 --18.5 0.5b -1.0b 33.5

Characteristics,

Co
11 10 -14.7 14.7 14.0 1.0

C
0.09 0.15 0.04 0.07 0.035 0.07b 0.05

Mn Si
-0.5b 0.2 -0.1
b

Mo W
10 10 3.0 3.0 3.0 7.0 ----1.5 1.25 ---

Cb Ti
--5.1 ----3.1 2.6 0.9 5.0 5.0 2.3 2.35

Al
1.5 1.0 0.5 2.5 2.50 2.1 0.85

B
0.010b 0.005 -0.02 0.033 0.005b --

Zr
----0.030 0.06b --

Other s
--0.2Cu --0.2bCu --

Typical applications
Jet engine blades, parts Gas turbine blades, parts, sheets Good weldability and fabricability Jet engine/rocket parts Sulfidation resistant disc alloy Sulfidation/impact resistance gas turbine alloy Gas turbine flame tubes

Rene 41 M-252, J1500 Inconel 718 Udimet 710 Udimet 720 Nimonic PK 33 Nimonic PE.11

Bal Bal 73.0 Bal Bal Bal 39.0

-0.5b 0.2 0.2b -0.5b --

0.5b --

f. Some superalloys such as inconel 718, Rene 41, Udimet 500, and others are made by more than one manufacturer. g. Maximum composition h. Compositions of Astroloy, Rene 77, and Udimet 700 are very similar. Certain elements are controlled to prevent sigma phase formation. i. Waspaloy A has a higher solution temperature and longer time at stabilization than Waspaloy B. Note: Many of the alloy designations are registered trademarks of producer companies. For example, Hastelloy, Haynes, and Multimet are registered trademarks of Cabot Co., and Incoloy and Inconel are trademarks of Huntington Alloys Co.

52

Fe-Ni-Cr Base Alloys

Alloys
a

Nominal composition, wt% Ni Cr

27 27.0 25 23.75 24.0 22.7 22.5 22.0 21.5 21 21 21.0 21 21 20.5 20.5

Characteristics, Typical applications

Fe
Bal Bal Bal Bal Bal Bal Bal Bal 30 Bal 46 28.0 Bal 46 Bal 44.5

Co
---

C
0.03b 0.08 0.05

Mn
2.5b 1.50b -1.0 1.0 0.2b 1.0b 1.0 0.5 -0.8 -1.5 0.8 1.25 0.8

Si
1.0b 1.0b -0.5 0.5 0.2b 0.8 0.4 0.2 1.7 0.5 -0.5 .4 0.40 0.5

Mo
3.5 --4.25 5.85 2.0 4.4 3.0 3.0 --3.0 3.0 -4.0 --

W
-------2.5 ----2.5 -4.0 --

Cb
-----1.1 ------1.0 (+Ta) -4.0 --

Ti
-0.40 ---2.5 0.7 -0.9 -0.4 2.1 ---1.1

Al
-0.4 ---1.5 -0.2 0.1 -0.4 0.3 -----

B Zr
-----0. 00 5 -----------------0.02 ---------

Others
1.0Cu 0.75bCu 0.7Nb 0.2N 0.5~1.5 Cu 2-4.0 Cu 0.015Pb 0.015Sb -0.6Ta, 0.02La 2.2 Cu 0.04Ce 0.17N 0.4 Cu -0.15 N, 0.50 Cub 0.4 Cu -0.2 Cu A sulfidation and corrosion resistant precipitation hardenable alloy Specially developed for auto-exhaust system. Heat exchanger, condenser tubing, stress-corrosion resistance Developed lately for oxidation resistance Furnace. Heat exchanger parts Surface & down-hole hardware in sour gas wells Gas turbine sheet parts Titanium creep-forming dies, ethylene furnace tubes Gas turbine parts, blades Petroleum hydrotreaters, heat exchangers Highly alloyed aus. SSS Excl. resistance to oxidizing & reducing environ. Excl. high temperature corrosion resist. Developed recently for more improved creep rupture strength.

Incoloy 028 Incoloy 803 Haynes HR-120 20Mo-4 20Mo-6 Pyromet 31 (carpenter) Incoloy 864 Incoloy 556 Incoloy 825 Aktiebolag 253 MA Incoloy 800 Incoloy 925 N-155, Multimet alloy Incoloy 802 S-590 Incoloy 801

31.5 34.5 37 37.5 35.1 55.5 34.0 20.0 42 11 32.5 44.0 20 32.5 20 32

----18.0 ----20 -20 --

0.03 0.03 0.04 0.08b 0.10 0.03 0.08 0.08 0.01 0.10 0.4 0.43 0.05

53

Alloys

Nominal composition, wt% Ni Cr

20.0 20.0 20.0 20 19.5 19 19 19 19 18.5 18.0

Characteristics, Typical applications

Fe
60.0 Bal Bal. Bal Bal Bal Bal 43 43 Bal --

Co
--0.02b ---------

C
-0.05 2.00b -0.08b 0.30 0.30 0.05 0.40 0.2 0.10b

Mn
-1.40 0.5b 2.0b 2.0b 1.10 1.00 1.5 1.5 -1.2

Si
-0.40 6.5 -0.5b 0.60 0.55 1.25 1.25 3.6 2.3

Mo
-2.25 -2.5 6.5 1.25 1.50 -----

W
-----1.20 1.20 -----

Cb
-0.15 ---0.40 ------

Ti
-----0.30 0.55 ---0.2b

Al
---0.07b -----1.0 --

B Zr
-----------------------

Others
--2.0Cu 3.5Cu 1.0Cu -----0.50bCu Specially developed for the seam-welded tubing Heat exchanger, condenser tubing, tress-corrosion resis Parts served in natural and acidic enviroments Excl. resistance in chloride, sulfuric, phosphoric & nitric acides Similar to RA-330 or RA-330 HC Excl. corros. Resist. To natural & acidic environ. Low-cost sheet, bar, forging alloy Similar to 19-9DL, no columbium and tantalum Heat exchangers, radiant tubes, etc. Higher strength than RA-330 Specifically developed for carburization resistance Good internal oxidation resistance due to addition of Si

Incoloy 840 Armco 20-45-5 Incology 25-6Mo Incoloy 020 Incology 330 19-9DL 19-9DX RA-330 RA-330 HC Rolled Alloys RA85H Incoloy DS

20.0 45.0 25.0 35.0 35.5 9.0 9.0 35 35 14.5 38.0

d. Some alloys are made by more than one manufacturer; e. Maximum composition; f. Cast alloy.

54

Ferritic Stainless Steels

Alloys
a

Nominal composition, wt% Ni Cr

29.0 29.0 29.0 27.0 26.0 26.0 26.0 26.0 26.0
25

Characteristics, Typical applications

Fe
Bal. Bal. Bal. Bal. Bal. Bal Bal. Bal Bal
Bal

Mo C
4.0 4.0 2.5 3.9 1.0 3.0 4.5 1.00 ---

Mn
0.05 0.3 2.0 1.5 0.01 1.00 1.0 0.75 2.50
1.50

Si
0.1 0.2 0.6 1.0 .025 0.75 0.75 0.75 1.00
1.00

Al
-----------

P
0.025 0.025

S
0.02 0.02

Ti
-----

Cu N Others
----

29-4-2 (AL) 29-4C (AL)

2.1 0.15 5.2 6.5 0.09 2.5 4.5 0.50 ---

0.003 0.01 0.03 0.04 0.001 0.025 0.25 0.06 0.08

0.20

0.015

7-Mo Stainless (Car) Alloy 255 (AL) E-Brite 26-1 Sea-cure/Sc-1 Monit 26-1 Ti 18-2FM
446

0.35
2.5 0.03 --0.2 ----

Superferritic, and high strength and corrosion resistance Superferritic, high strength and corrosion resistance A duplex structure with 85% ferrite and 15% austenite. A duplex structure with 50% ferrite and 50% austenite. Designed for comb. of high strength and exc. coro. res. Superferritic, high corrosion resistance Superferritic A duplex structure

0.25 0.01 --0.04 -0.25 1.0Cu

0.02 0.04 0.04 0.04 0.04 0.04 0.04b

0.02 0.03 0.03 0.02 0.15 0.03 0.0b

-0.3 0.6 0.6 ---

Carpenter 443
442

---

20.5
20.5

Bal
Bal --

--

0.2b
0.20

1.0b
1.00

1.0b
1.00

--0.04 0.02 0.03 0.03b

------

--

Free-machining alloy with corrosion resistance similar to that of 303 More Cr than 442 for more improved scaling resistance Corrosion and mechanical properties close to 18-8 austenitic stainless steels Equivalent to Carpenter 443

AL 453TM

0.3

22.0

Bal

--

0.03

0.3

0.3

0.6

0.02

0.10b (Ce+La)

For SOFC applications due to its TEC match and excellent oxidation and scaling resistance.

55

Ferritic stainless steels (cont.) Alloys

AL 433
a

Nominal composition, wt% Ni Cr

20.0 20.5 18.5 18.25 18.0 18.0

Characteristics, Typical applications

Fe
Bal Bal Bal Bal Bal Bal

Mo C
--2.10 ---0.01 0..20 0.025 0.009 0.009 0.012

Mn
0.30 1.00 1.00 0.40 0.35 0.45

Si
0.39 1.00 1.00 0.55 0.34 0.55

Al
---0.03 0.05 --

P
0.021

S
0.001

Ti
--0.4 0.10 0.29 0.40

Cu N
--

Others
0.54 Cb, 0.80b

TM

0.25 -1.00 0.22 0.30 0.23

0.019 -0.035 0.016 0.014 0.013

Carpenter 443 444 ( 18-2) AL 468TM AL 441 HPTM AL 439 HPTM

0.04b 0.04 0.024 0.023 0.02

0.03b 0.03 0.001 0.002 0.001b

1.10 -----

Superferritic, in the family of 409 and 439. Combining oxidation resistance and high temp. strength. As modified type of 430 for higher corrosion resistance.
More Mo than 442 for higher corrosion resistance

0.25 Cb 0.71 Cb 0.8b Ti+Cb

Cb stabilized, reducing Ti and thus the Ti related defects as in 439

Good oxidation and corrosion resistance for auto. Exhaust application. A titanium stabilized alloy, more weldable than 430.

Sealing glass stainless steels

Carpenter 27 AL 430Ti Carpenter 18
0.5b 28.0 20.0 -18.0 Bal Bal Bal -0.10 0.60 0.40 -0.40 --0.05 0.60 0.40 ----

Sealing glass material. No phase transformation till 1050oC Modify 430 for sealing glass appl. Sealing glass composition with exactly TEC match

56

Co Base Alloys
Alloys
a

Nominal composition, wt% Ni Cr Fe

30.0 31.0 28.0 28 1.0 3.0b 21.0 20.0

Characteristics, Typical applications

Co
61.5 59.0 49.0 Bal

C
1.0 1.6 0.12b 0.08

Mn
1.4 2.0b -0.65

Si
-2.0b -0.35

Mo
1.5 1.50b -1.5b

W
4.0 4.50 ---

Cb
-----

Ti
-----

Al
-----

B
-----

Zr
-----

Others
----Solid solution alloy, as L-605, Haynes 188, s-186 Machine knives Solid solution alloy Resistant thermal shock, high temperature corrosion (air & air-SO2) Appli. For severe corrosive attack env. High strength and oxidation resistance >Hastelloy X; Aero-burner cans, after burner components

Haynes 6B (Stellite) Haynes 6K (Stellite) UMCo-50 Haynes 150 ULTIMET Haynes 188

3.0 2.0 -3.0b

9 22

26 22

3 3.0b

54 Bal

0.06 0.10

0.8 1.25b

0.3 0.3

5.0 --

2.0 14

---

---

---

---

---

-0.04La

e. Some alloys are made by more than one manufacturer f. Maximum composition g. Cast alloy.

57

Cr-Base Alloys
Alloysa Ni Cr Fe Co C
C207 CI-41 IM-15 Chrome 30 Chrome 90 Chrome 90S Ducrolloy (Plansee) -------Bal Bal Bal Bal Bal Bal Bal ------5.0 -------0.10 0.09 ---0.5 ------------0.5 1.0 --7.1 ------

Nominal composition, wt% Mn Si Mo W Cb Ti Al B

7.5 -------------0.2 --0.5 -0.5 ----------0.1 -----

Characteristics, Typical applications

Zr Others
0.8 ------0.15Y 0.2 (Y+La) 2.0 Ta 1.7 Ta 0.1 Y 6MgO 3MgO, 2.5V 3MgO, 2.5Ta 1.0 Y2O3 Developed by GE Developed by GE Developed by NASA & Westinghouse Bendix (Navy) Bendix (Navy) Bendix (Navy) Specifically developed for SOFC applications Made by PM approach

58

Alumina Forming Alloys

Alloys
a

Nominal composition, wt% Ni Cr Fe Co

15.0 15.0 17.6 15.0 15.0 15.0 16 19.0 1.0b -3.0 -0.5b 1.0b -0.5b 14.0 --15 18.5 18.5 -18.0

Characteristics, Typical applications

C
0.16 0.05 0.05 0.06 0.07 0.15b -0.08

Mn Si
1.0b -0.5 -0.2b ---1.0b -0.2 ------

Mo W Cb Ti Al Ni-Cr-Fe Superalloys
4.0 2.0 -525 5.0 5.2 -4 -4.0 --------------4.0 2.5 -3.5 3.5 3.5 -3.0 5.0 4.5 4.5 4.4 4.4 4.25 4.0 3.0

B
0.002 0.01 0.01 0.03 0.025 0.05b -0.007

Zr
0.15b 0.15 0.1 ------

Others
0.2bCu 1.1 Y2O3, 2.0Ta 0.01Y -----Turbine blades IN MA-6000E Developed for excellent Oxidation resistance Forgings at high temp. Jet engine parts Jet engine parts ODS (Al2O3) alloy Gas turbine parts/sheets/bolts

Nimonic 115 IN MA-6000E Haynes 214TM Astroloyd Udimet 700 Rene 77d HAD 8077 Udimet 500

Bal 68.5 Bal Bal Bal Bal Bal Bal

Incoloy MA 956

0.50b

20

Bal

0.30b

0.10b

0.30b

Fe-Ni-Cr Superalloys
----0.5 4.5 --0.5Y2O3 MAed ODS alloy, applications in turbine chambers or energy conversion

59

Alloys

Nominal composition, wt% Ni Cr Fe Co C Mn Si Mo W Cb Ti Al

-------

Characteristics, Typical applications

Zr Others
--0.25N -0.3Y

Ferritic Stainless Steels

Kanthal (APM) Fecralloy Armco 18 SR --0.25 22 15.8 18.0 Bal Bal. Bal. ---0.08 0.03 0.015 --0.30 ---1.0 -----0.4
6.0 4.8 2.0

----

Co Base Superalloys
AiResist 215c AiResist 13c AiResist 213 -1.0b -19 21 19 -2.5b -Bal Bal Bal 0.35 0.45 0.18 -0.5b -------4.5 11 4.7 -2.0 ----4.3 3.5 3.5 ---0.13 -0.15 7.5Ta, 0.17Y 0.1Y 6.5Ta, 0.1Y Nozzle vanes; resistant to hot corrosion High temperature parts Sheets, tubing; resistant to hot corrosion

60

Appendix C Properties of Selected Alloys I. Ni-Cr or Ni-Cr-Fe Base Alloys

Alloys TEC 10 .K
Inconel 671 IN 657 Inconel MA 758 Nimonic 81 Haynes G-30 Inconel 690 IN-587 Haynes HR-160 NA-224 Nicrofer 6025HT-602CA -6 -1

Electrical resistivity (bulk) 10-6 .cm 86.9

~80-90

Yield strength 0.2 (bar) (MPa)

800oC

Elastic modulus (GPa)

Oxidation Corrosion Resistance resistance: corr.=HCR 10-6 mg2. Hot Carbariz.=CR -4 -1 Stress corr.=SCR cm .s
Super, Esp. HCR

Joinability

Formability or Elongation . 25%

Others Cost
factor
Machinability (%) H resistance=HR Scaling resist.=SR

15.0

20-800 C

225

~15.0 15.0

20-800oC 20-760oC

14.6
760oC

1,000oC Exc. HCR Exc. HCR

114 127 116 115 ~100-120 112 ~100-120 118

560

228
RT

24%

11.1 ~15.0
20-100-800oC

16.0 16.5

30-760 C 20-760oC

202
538 C 800oC
o

184
538 C
o

Super esp. in phosp. Exc. HCR Exc. HCR

Readily Readily

56% 41% 28%

16%

170

211
RT

~16-17
RT-800oC

663 215
o

760oC

16.6

RT-800 C

158
800 C
o

Exc. HCR, CR >556, 800H Exc. HCR

Readily

68% 12

760 C

~16-17
RT-800 C
o

16.6

RT-800oC

220 ST
800oC

154

800oC

Excellent HCR good CR

Readily

30%

Good HR

61

Alloys

TEC 10 .K ~15-16
RT-800oC RT-800 C
o

-6

-1

Nimonic 86 RA-333 IN-597 Nimonic 101 Inconel 601 Hastelloy C-2000 IN-939 Haynes 230 Inconel 617 Hastelloy G Hastelloy G-3 Hastelloy X Hastelloy HX Pyromet 680

Electrical resistivity (bulk) 10-6 .cm ~100-120 ~100-120 ~100-120 ~100-120 119 128 123 125 122 ~100-120 ~100-120 118
116 118

Yield strength 0.2 (bar) (MPa)

Elastic modulus (GPa)

Oxidation Corrosion Resistance resistance: corr.=HCR 10-6 mg2. Hot Carbariz.=CR Stress corr.=SCR cm-4.s-1
Exc. HCR Excellent HCR

Joinability

Formability or Elongation 41%

Others Cost
factor
Machinability (%) H resistance=HR Scaling resist.=SR

20% 5.1

~17-18 ~16-17
RT-800oC RT-800oC

663

760oC

15% 129
800oC Low in NaCl env<N.80A,90

~16-17 16.5
27-760oC

Good
Readily Readily 45% in 2in Exc.

10% 4.0
20% Exc. SR.

760oC

200 SP

155 372
RT

760oC

12.2

14.0 14.0 15.2

11.6

20-700 C 20-800 C 25-800oC 20-100oC

o

1,000oC Exc. both ox & re env

Good HCR Good CR Exc. HCR, CR in Both ox & re env

63%
3.5%

690
760 C 760oC
o

150
800 C
o

Exc. 5.5
1,100 1,000oC

285 350

164 211
RT

800oC

2.2

Exc. HCR Good CR Good HCR Good HCR Exc. CR Exc. in intergranular CR

Readily Readily Readily Readily Readily Readily Readily

48% 58% 50% 50%

12.3 mm O 43%

Moderate MB as all solution alloys

RT

16.4 14.6 16

21-650 C 20-100 C 26-816oC

o

220 s
760 C
o

160
145 C
o

18%
18%

320
RT 760oC

199
RT

262 s

196
RT

1,100oC

69.4

Good HCR Good SCR Good Good HCR Good SCR

5.2

18% 18%

16.1 16.0

26-816oC 26-816 C
o

261 241
o

760oC 760 C

143 144
o

800oC 816 C

45.5% 50.0

62

Alloys

TEC 10 .K 15.3
21-760oC -6 -1

Hastelloy C-22 Inconel 625 Inconel 622 Inconel 686 Inconel 725
TM

Electrical resistivity (bulk) 10-6 .cm 114 128 122

Yield strength 0.2 (bar) (MPa) 269 s

760oC

Elastic modulus (GPa) 163

760oC 760 C
o

Oxidation Corrosion Resistance resistance: corr.=HCR 10-6 mg2. Hot Carbariz.=CR Stress corr.=SCR cm-4.s-1
Exc. HCR, SCR

Joinability

Formability or Elongation 62% 50% 62% 60% 35%

Others Cost
factor
Machinability (%) H resistance=HR Scaling resist.=SR

Superior

20% 16-18%
Structure & prop. Stable with temp. Exc. HR

15.3 14.1

21-760 C 21-982 C
o

421
760 C
o

160 200
760 C
o

69.4
1,100 C
o

Exc. HCR and SCR Exc. HCR, SCR Ox & re env. Exc. Exc. HCR

Readily Readily Readily

210
760 C 530oC 760oC
o

12.0 ~16.5 123.7

20-100-800oC 20-100-800oC

245 s

13.0 ~17.0 114.4 13.0~17.0

26-93-800 C
o

500

Hastelloy G-50 Hastelloy D-205 TM Nimonic 263 RollsRoyce263 IN-853 Inconel MA 754 Inconel 050 TDNiC Nimonic 75

~100-120 ~100-120 115 ~100-120 108 ~100-120 119 ~100-120

993
RT

192
RT

Good HCR Exc. HCR, SCR in acidic media

Readily Readily

19% 56.5% Exc. 9%

Silica forming alloy

~16~17.0
RT-800 C
o

337
RT 760oC

15.4

20-800oC

515

166

Good HCR

Readily

800oC

16% 16%

~16-17 12.2 ~15

26-93oC

RT-800oC

559 400

760oC 760oC

Exc.

Readily

20% 20% 41% 15% 6%

26-93-800oC

760oC

262 s Good

Readily Readily

16.2 ~15

20-760oC Nimonic 95

185

760oC

RT-800oC

1100
760oC

Readily

63

Alloys
Nimonic 90 (pyromet 90) Waspaloy Ad Waspaloy Bd Nimonic 80 Nimonic 80A Udimet 520 Haynes R-41 Pyromet M-252, (carpenter) Inconel 718 Udimet 710 Udimet 720 Nimonic PK 33

TEC 10 .K 16.2
20-760oC -6 -1

Electrical resistivity (bulk) 10-6 .cm 114 124 124 117 ~100-120 130.8 ~100-120 121 aged 127 annealed ~100-120 ~100-120 126

Yield strength 0.2 (bar) (MPa) 538

760oC 760oC

Elastic modulus (GPa) 214

RT

Oxidation Corrosion Resistance resistance: corr.=HCR 10-6 mg2. Hot Carbariz.=CR Stress corr.=SCR cm-4.s-1
Good in NaCl > N.101, 91

Joinability
Readily Readily

Formability or Elongation 23% 25% 38% 24% 21%

Others Cost
factor
Machinability (%) H resistance=HR Scaling resist.=SR

10% 14%
Close to N.75, ex. more Al and Ti 18%

15.4 12.7 16.5 ~15

20-800oC

676

164

800oC

16

1000oC

Good
Good HCR Good in NaCl > N.101, 91

Close to Waspaloy A, except no addition of 0.02S and 0.1 Cu for improved machinability.
20-100oC 20-800 C 25-800oC
o

660 504
o

760oC 760 C

Good

Readily Readily

725 752

760oC 760oC

15.2 14.0 16.0

20-800oC 20-816oC 21-760oC

169 156

800oC 760oC

6.5

Good HCR Good HCR Good HCR

1000oC

Less Readily
Readily

16.6% 25% 21% 17% 7%

<10% (difficult) 14-16%

718 739

760oC 760oC

Exc. 40

Up to 982oC

154

Readily
PT &ST

760oC

1,100oC

~15-16
RT-800oC RT-800oC

829 814 620

760oC 760oC Good HCR

~15-16 12.1
20-100oC

Readily

800oC

33%

64

II. Fe-Ni-Cr Base Alloys

Alloys TEC Electrical RT~800oC resistivity (bulk) -6 -1 10-6 .cm 10 .K 16.7
99

Incoloy 028 Incoloy 803 Haynes HR-120 20Mo-6 20Mo-4 Pyromet 31 (carpenter) Incoloy 864 Incoloy 556TM Incoloy 825 Aktiebolag 253 MA Incoloy 800

20-426oC

Yield strength 0.2 (MPa) 214

RT 760oC

Oxidation Corrosion Elastic Modulus Resistance resistance: corr.=HCR 10-6 mg2. Hot Carbariz.=CR -4 -1 (GPa) Stress cor.=SCR cm .s Exc. in both 200 Oxi. & red. Env.
RT RT

Joinability

FormCost ability or Elongation factor 40% 46%

Others
Machinability (%) H resistance=HR Scaling resist.=SR

17.1 17.3

21-649oC 26-800oC

103 105 108 106 122 104 95.2 113 84 99 116 93 ~100-120

215

195 197
RT

Exc. HCR, CR Good SCR Exc. HCR, CR Good SCR Exc. HCR, CR Good SCR Good SCR Exc. HCR, SCR Readily Readily Readily Readily Readily Exc. HCR, CR Good SCR Readily Readily Readily Readily

Exc. resist. To cyclic oxidation

375 s
RT

50% s 50% 41% 41% 41% 47.7% 45% 51% 44% 24% 43%

3.5

16.87 16.87
o

26-800oC 26-800 C

275
RT

186
RT

262
RT 760oC 760oC 760oC

186
RT

16.1

21-816oC

669 140

154 195
RT

816oC

16.4
16.7

21-649oC 26-800oC

For exhaust gas recirculation tubes 8.5

220
o

148 206
RT

800oC

17.1 19.0 14.4 13.2

17.5

26-760 C 26-760oC 20-100oC Incoloy 925 N-155, Multimet alloy Incoloy 802

183
760 C 760oC 550oC

3.3

1,000 C. < alloy 601

Exc. HCR, CR Good SCR

110 213

115 193
RT

760oC

Good.
Exc. HCR, CR Good SCR Exc. HCR, CR Good SCR

2.3 16%
SR.<that of 310 (poor)

2.7

1,000oC Exc. both reduc. & oxid.

25-93oC 26-800oC

639oC

640 ps 214
RT

Readily Readily

393
RT

Good

16-20%

~16-18
RT-800oC

65

Alloys
S-590 Incoloy 801

TEC Electrical o RT~800 C resistivity (bulk) -6 -1 10-6 .cm 10 .K ~100-120 ~16-18

RT-800oC RT-800 C
o

Yield strength 0.2 (MPa) 197

RT

Oxidation Corrosion Elastic Modulus Resistance resistance: corr.=HCR 10-6 mg2. Hot Carbariz.=CR (GPa) Stress cor.=SCR cm-4.s-1 207
RT Same as 801 Same as 801

Join- FormCost ability ability or Elongation factor

Others
Machinability (%) H resistance=HR Scaling resist.=SR

~16-18

~101.2

53%

20%

Incoloy 840 Armco 20-45-5 Incology 25-6 Mo Incoloy 020 19-9DX 19-9DL RA-330

Low Ni alloy developed for the manufacture of the seam-welded tubing used for the sheathing of electrical resistance heating elements.

~16-18
RT-800oC

~100-120 80 108 77 101.7

760oC 760oC

16.9 16.8 18.0 18.0

21-649oC 20-100oC

170 160 138

188
RT

Exc. in natural & acidic env. Exc. HCR, CR Good SCR

42% 41%
Readily

6.5% Si may be too high for SOFC

Close to 19-9DL
20-816oC 20-760oC 816oC 760oC Exc. upto 677oC Exc. upto 677oC Exc. HCR, CR Good SCR

39% 45% 2.8

Cycl. oxid. resis. Not good

140

117

760oC

RA-330 HC Rolled Alloys RA85H Incoloy DS

Close to RA330

~16-18
RT-800 C
o

~100-120 108 140

760 C
o

Exc. CR Exc. CR

15.0

20-100 C

60%

Exc. internal oxidation resist.

66

III. Ferritic Stainless Steels

Alloys TEC Electrical RT~800oC Resistivity (bulk) -6 -1 10-6 .cm 10 .K ~60-80 9.4
20-100oC RT-400oC

Yield strength 0.2 (MPa)

655 605 RT 400oC

29-4-2 (AL) 29-4C (AL)

Oxidation Corrosion Elastic Modulus Resistance resistance: corr.=HCR 10-6 mg2. Hot Stress cor.=SCR -4 -1 (GPa) Carbariz.=CR cm .s Exc. 207 Comp. to supera
RT RT

Joinability

FormCost ability or factor Elongation 25% >20% 31% >20% 30% >20% >20% >20%

Others
Scaling resist.=SR Machinability (%) H resistance=HR

Fairly Fairly Readily Readily Fairly Fairly Readily Fairly Fairly Fairly Fairly Fairly

Exc. SR Exc. SR

10.4

~60-80 77.5 82.1

o

500
RT

207 200
RT

Exc. >E-Bite, 446 at 800oC

Exc. HCR, SCR Exc. HCR, SCR Exc. HCR, SCR

7-Mo Stainless (Carpenter) Alloy 255 (AL) E-Brite 26-1 Sea-cure/Sc-1 Monit 26-1 Ti 18-2FM 446 AL 453TM

13.3 14.7 13.8

25-500 C
o

25-538-760oC

565
RT

>480
RT

9.9 11.8
20-100-500 C

~60-80 ~60-80 ~60-80 ~60-80 ~60-80 67 73.3 68

>275
RT

5.4

1,000 C

Exc. <29-4-2 Exc. HCR, SCR Exc. HCR, SCR Exc. HCR, SCR Exc. HCR, SCR

Good SR

~13

RT-800oC

>380
RT

~13-14
RT-800oC RT-800 C
o

>550
RT

~12-13 ~12
RT-800 C
o

>275
RT

10.4 11.2

20-100-538oC RT-538-816oC

>275 <55* RT 760oC 310 39 RT 760oC

200
RT

2.6

Exc. Exc. HCR, SCR Good

1,000oC 760oC

>20% 35% >20%

1 1

Good SR * tensile strength Exc. SR Good SR

11.4 12.3
o

200
RT (est.)

0.22

Carpenter 443

12.1

>275
RT

200
RT

20-649 C

67

Ferritic stainless steels (cont.) Alloys TEC Electrical RT~800oC Resistivity (bulk) 10-6.K-1 10-6 .cm 65 11.80
RT-650oC Carpenter 443 AL 468TM

Yield strength 0.2 (MPa)

325 80 RT 760oC 345 41 RT 760oC 282 62.0 RT 760oC 290 57.8 RT 760oC 310 48.8 RT 760oC

AL 433TM

Oxidation Corrosion Elastic Modulus Resistance resistance: corr.=HCR 10-6 mg2. Hot Stress cor.=SCR -4 -1 (GPa) Carbariz.=CR cm .s 0.10 Good 200
RT 815oC

Joinability

FormCost ability or factor Elongation 32% 22% 33%

Others
Scaling resist.=SR Machinability (%) H resistance=HR

12.10 12.50 11.3

RT-650oC RT-800 C
o

~ 60-70 63 58.7 63

200
RT

Good 0.17 0.10 0.20

815oC 815oC 815oC

200
RT

Good
Good Good. Fairly Fairly

AL 441 HPTM AL 439 HPTM

RT-800 C

200
RT

31.0% 34%
Good SR

12.50

RT-800oC

200
RT

Sealing-glass alloys
AL 430Ti Carpenter 18 Carpenter 27

9.9 11.3
RT-200-500 C
o

60 63

310
RT

200
RT

Good Good

25% 25%

Exactly TEC match with glass Exactly TEC match with glass

10.0 11.0

RT-200-500oC

345
RT

207
RT

68

VI. Co-Base Alloys

Alloys
Haynes 6B (Stellite) Haynes 6K (Stellite) UMCo-50 Haynes 150 Haynes 188

TEC Electrical RT~800oC resistivity (bulk) -6 -1 10-6 .cm 10 .K 91.0 16.3

0-800oC

Yield Elastic strength Modulus 0.2 (GPa) (MPa) 260

860oC

Oxidation Hot Resistance Corrosion 10-6 mg2. resistance cm-4.s-1

Exc. SCR, HCR Exc. SCR, HCR

Joinability
Readily

FormCost ability or Elongation factor 17% 4%

Others
Machinability (%) H resistance=HR Scaling resist.=SR

14.5 16.8 16.9 16.5

~60-90
o

0-800oC

310 150
o

815oC

82.5 87 101

215
RT

Exc. SCR, HCR Exc. SCR, HCR Close 230 >X,617,625 Excellent HCR >230

Readily Exc. Readily

8% 38% 56%
Welding mater.

20-1000 C 25-760 C 20-800oC

o

700 C

275
538 C 760oC
o

180
649 C
o

290 s

169 s
800oC

12-14%

69

V. Cr-Base Alloys
Alloys TEC Electrical RT~800oC resistivity (bulk) -6 -1 10-6 .cm 10 .K Yield strength 0.2 (MPa) Oxidation Hot Elastic Modulus Resistance Corrosion 10-6 mg2. resistance (GPa) cm-4.s-1 Join- FormCost ability ability or Elongation factor Others
Machinability (%) H resistance=HR Scaling resist.=SR

C207 CI-41 IM-15 Chrome 30 Chrome 90 Chrome 90S Ducrolloy (Plansee)

11.8

20-1000oC

1,000oC

4.60

Exc. HCR, SCR

<10%

70

VI. Alumina Forming Alloys

Alloys TEC Electrical RT~800oC resistivity (bulk) -6 -1 10-6 .cm 10 .K
~16-18 20-800oC 20-800oC ~16-18 20-800oC ~16-18 20-800oC ~16-18 20-800oC ~16-18 20-800oC ~16-18 20-800oC

Yield strength 0.2 (MPa)

Oxidation Hot Elastic Modulus Resistance Corrosion 10-6 mg2. resistance (GPa) cm-4.s-1
Excl. SCR, HCR Super. SCR, HCR Excl. SCR, HCR Excl. SCR, HCR Excl. SCR, HCR Good. SCR, HCR Good. SCR, HCR Good HCR

Joinability

FormCost ability or factor Elongation

Others
Machinability (%) H resistance=HR Scaling resist.=SR

VI. Ni base superalloys

Nimonic 105 Haynes 214TM IN MA-6000E Astroloyd Udimet 700 Rene 77
d

~120-140 134 ~120-140 ~120-140 ~120-140 ~120-140 ~120-140 120.3

760oC 760oC

Readily
Readily

16.6

640.5

800oC

162

Super >> alloy 230

36.8%

Good SR, HR 18% Good SR, HR Good SR, HR Good SR, HR 12% Good SR, HR Good SR, HR Good SR, HR

Readily Readily Readily Readily Readily Readily

13

1,000oC

HAD 8077 Udimet 500

13.3

20-100oC

731

32%

12%
Good SR, HR

Fe base superalloys
MA956

11.3

20-100 C

131

120
800 C
o

Super. SCR, HCR

9%
Exc. SR, HR

71

Alloys

TEC Electrical o RT~800 C resistivity (bulk) -6 -1 10-6 .cm 10 .K

Yield strength 0.2 (MPa)

Oxidation Hot Elastic Modulus Resistance Corrosion 10-6 mg2. resistance (GPa) cm-4.s-1

Joinability

Formability or Elongation

Others Cost
factor
Machinability (%) H resistance=HR Scaling resist.=SR

Co base superalloys
AiResist 215c AiResist 213 AiResist 13c

4%

VII. Ferritic Stainless Steels

Kanthal (APM) Fecralloy

16.3

20-1000oC

~120-140
>550 <100 RT 800oC

1.0 200 (est)

11.1 12.2* 134

20-100 650oC

1,000oC

Super. SCR, HCR

Exc. SR

<25%

Exc. SR

* Tested at PNNL

72

VI.Selected Elemental Metals and Intermetallics

Alloys
Silver FCC Gold FCC Platinum FCC Nickel FCC Copper FCC Chromium BCC Aluminum FCC Titanium HCP Fe3Al Ordered BCC Ni3Al Ordered FCC

TEC Electrical RT~800oC resistivity (bulk) -6 -1 10-6 .cm 10 .K 20.61 1.7

0-500 C
o

Yield strength 0.2 (MPa) 55

RT

Vapor pressure (Pa) 10-2

800oC 10-22 800oC

Elastic Oxidation Melting Modulus Resistance point (oC) 10-6 mg2. (GPa) cm-4.s-1 71 961
RT

Joinability

FormCost ability factor or Ductility 30% 35%

Others
H resistance Scale adherence machinability

14.2
20oC

2.4
o

125
RT

74.5
RT

1064 1769 1433 1084 1875 660 1875

9.1

10.6 6.8 10 130 26.5 420

150
RT

156
RT

20-100 C

13.3 18.9 16.5 23.0

20 800oC

20-100~1000oC

>150
RT

207 1.3x10-3
946oC
RT

6.2
RT 23.6 20~100oC

282
RT

10-4

965oC

68 <100> 248 62

10~35
(annealed)

8.4 10.1
20 1000 C
o

140

10-5

800oC

141 12.3 15.6

20 800oC

1540 Limited >650oC 1390

500 (est)
800oC

178

73

Notes:
1. Yield strength 0.2 (bar) (MPa): yield strength at 0.2% offset. Normally data from bar tests at a temperature around 800oC is collected. If bar test data is not available, the sheet test data is used and marked as B in tables. Typically a yield strength from a bar test is higher that that from a sheet test. 2. Oxidation resistance is measured by the parabolic rate constant in unit of mg2. cm-4.s-1 3. Corrosion resistance: including hot corrosion (sulfidation) and carburization resistance, abbreviated as HCR and CR respectively. 4. Formability: measured by Erichsen or Olsen cupping depth (mm), marked as E and O, respectively. If the E or O cupping depth at room temperature (RT) is not available, the elongation data from bar tests is colleted as alternatives for comparison. The data from sheet tests will be used and marked as S in case bar test data is not available. 5. The (bulk) electrical resistance at room temperature is used here. The resistance usually increases with temperature, but normally the resistance (increasing) coefficient is small. The resistance at room temperature provides enough information for evaluation of electrical resistance of alloys. 6. Cost factor is the ratio of ($/lb of alloy) /($/lb of stainless steel 446) in mils sheet. 7. Machinability of alloys is expressed as a percentage by referring Seco Tools AB. Decreasing values indicate increasing machining difficulty.

Abbreviations:
RT: room temperature ST: solution treated; PT: precipitation treated; SP: solution + precipitation treated; OCD: typical Olsen cup depth; SSS: stainless steel; ~: Estimated by authors.

74