Corrosion of the bonding at FeCrAl/Zr alloy interfaces in steam

The interfacial bonding at protective coatings and Zr alloy substrates could have a significant effect on the corrosion behaviors of the coatings. In this work, FeCrAl-Zr couples were fabricated at 900 °C by spark plasma sintering (SPS), and the interfacial bonding of the couples was modified through the addition of Si and/or thermal diffusion at 1100 °C-1300 °C. Uphill diffusion of silicon occurred during SPS. The corrosion resistance of the couples in 400 °C/10.3 MPa steam, and the effects of the interfacial bonding characteristics were studied. Due to the presence of ZrSi2 in the interfacial layer, the interfacial bonding of the FeCrAl/Si-Zr couple had a better corrosion resistance than that of the FeCrAl-Zr couple, withstanding 14 days of corrosion in steam compared to 7 days for the FeCrAl-Zr couple. The results also suggested that bimetallic effect could accelerate the oxidation of Zr alloy at the interface of the couples, and galvanic corrosion significantly contributed to the serious corrosion of the interface of the diffusion bonded couples with thermal diffusion. The influence of oxide growth stress around interface on the bonding lifetime of the couples was also discussed.