Influence of Al and Fe additions on metal dusting of NiCr alloys

Abstract Corrosion by metal dusting causes problems in various industries that process carbonaceous gases. Recently, the chromium‐ and aluminum‐rich Ni‐based Alloy 699 XA was introduced as a material with high resistance against metal dusting attacks. In this study, the metal dusting degradation of Alloy 699 XA and model alloys was investigated. In the model alloys, the aluminum, chromium, and iron contents were varied to analyze the role of each element systematically. Alloy 602 CA was included as a reference material. It was found that the alloys with the highest chromium and aluminum contents (30 and 2–3 wt%, respectively) showed the highest resistance against metal dusting. Also, the limited addition of iron enhanced the aluminum activity and thereby promoted the formation and maintenance of an aluminum‐rich oxide scale. This effect at low iron levels is contrary to the negative impact of iron at higher levels, which typically leads to an increased metal dusting susceptibility. Exposure tests were performed with two gas mixtures having similar compositions, but different carbon activities. It was found that both gases had a similar aggressiveness regarding metal dusting attacks.