Simulation of high-temperature oxide and sulfide-oxide corrosion of Fe76Cr24 alloy based on a coupled model of chemomechanics
DOI:
https://doi.org/10.7242/1999-6691/2026.19.1.6Keywords:
oxidation, sulfate-induced hot corrosion, chemomechanics, coupled model, interdiffusion, stressesAbstract
The operation of gas turbine engine parts at elevated temperatures in aggressive environments containing oxygen and sulfur compounds leads to the formation of a corrosive film that changes the mechanical characteristics and stress state in the surface layer. This, in turn, affects the rate of propagation of the corrosion product. High-temperature salt corrosion of metal alloys is accompanied by inter-diffusion and chemical reactions between metal components and aggressive substances, swelling of the material and the occurrence of rheological strains. For this reason the description of this process must be carried out within the framework of a coupled formulation. For the theoretical description of the process, a model based on the classical thermodynamics of irreversible processes is used. It includes the equations of mass balance of the components and the equilibrium equation for the material as a whole, and takes into account the elastic-viscous-plastic behavior of corrosion products at elevated temperatures. The COMSOL Multiphysics finite element package was used to calculate the processes of high-temperature oxidation and sulfide-oxide corrosion of a two-component iron and chromium alloy. Analysis of the results obtained showed the formation of a layered structure of a corrosion film, the advance of the front of compressive residual stresses and corrosion deep into the material, and stress relaxation near the surface. A comparison of geometrically linear and nonlinear formulations of the model, considering or ignoring the influence of stresses on diffusion flows and chemical reaction rates, as well as plastic and viscous strains, revealed a significant effect of each of these factors on the propagation velocity of the corrosion front and on the stress-strain state of the material.
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