Alumina Scale Formation on a Powder Metallurgical FeCrAl Alloy (Kanthal APMT) at 900–1,100 °C in Dry O2 and in O2 + H2O

A Rapidly Solidified Powder (RSP) metallurgical FeCrAl alloy, Kanthal APMT, was exposed in dry and humid O2 for 72 h at 900–1,100 °C. The formed oxide scales were characterized using gravimetry in combination with advanced analysis techniques (SEM, EDX, TEM, XRD, AES and SIMS). The oxide scales were at all exposures composed of two-layered α-Al2O3 scales exhibiting a top layer of equiaxed grains and a bottom layer containing elongated grains. A Cr-rich zone, originating in the native oxide present before exposure, separated these two layers. The top α-Al2O3 layer is suggested to have formed by transformation of outwardly grown metastable alumina, while the inward-grown bottom α-Al2O3 layer had incorporated small Zr-, Hf- and Ti-rich oxide particles present in the alloy matrix. The scale also contained larger Y-rich oxide particles. Furthermore, in the temperature range studied, the presence of water vapour accelerated alloy oxidation somewhat and affected scale morphology.