Transient scaling, high-temperature alloys

It is important to realize that corrosion rates may be controlled by any of several thermodynamic or kinetic properties of the alloy-scale-environment system and not just by surface or interface reactions. The three stages of high temperature oxidation of a metal, shown schematically in Fig. 1, serve as an example (7). The first or transient stage includes initial gas adsorption, two-dimensional oxide nucleation, initial three-dimensional oxide formation and finally, formation of the dominant oxide that will control the oxidation rate in Stage II. Various portions of Stage I have been widely studied using surface analytical techniques, but its duration can be very short and it is usually assumed (not always correctly) that Stage I has little impact on ultimate corrosion properties of the material. 

In selecting metals and alloys as materials of construction, one must have knowledge of how materials fail, for example is, how they corrode, become brittle with low-temperature operation, or degrade as a result of operating at high temperatures. Corrosion, embrittlement, and other degradation mechanisms such as creep will be described in terms of their threshold values. Transient or upset operating conditions are common causes of failure. Examples include start-ups and shutdowns, loss of coolant, the formation of dew point water, and hot spots due to the formation of scale deposits on heat transfer surfaces. Identification and documentation of all anticipated upset and transient conditions are required. 

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