Classifications

• • C—CHEMISTRY; METALLURGY
  • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
  • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
  • C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
  • C23C8/06—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases
  • C23C8/08—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases only one element being applied
  • C23C8/10—Oxidising
• • C—CHEMISTRY; METALLURGY
  • C21—METALLURGY OF IRON
  • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
  • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
  • C21D1/74—Methods of treatment in inert gas, controlled atmosphere, vacuum or pulverulent material
• • C—CHEMISTRY; METALLURGY
  • C21—METALLURGY OF IRON
  • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
  • C21D3/00—Diffusion processes for extraction of non-metals; Furnaces therefor
  • C21D3/02—Extraction of non-metals
• • C—CHEMISTRY; METALLURGY
  • C21—METALLURGY OF IRON
  • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
  • C21D6/00—Heat treatment of ferrous alloys
• • C—CHEMISTRY; METALLURGY
  • C21—METALLURGY OF IRON
  • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
  • C21D6/00—Heat treatment of ferrous alloys
  • C21D6/002—Heat treatment of ferrous alloys containing Cr
• • C—CHEMISTRY; METALLURGY
  • C21—METALLURGY OF IRON
  • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
  • C21D6/00—Heat treatment of ferrous alloys
  • C21D6/008—Heat treatment of ferrous alloys containing Si
• • C—CHEMISTRY; METALLURGY
  • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
  • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
  • C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
  • C23C8/06—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases
  • C23C8/08—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases only one element being applied
• • C—CHEMISTRY; METALLURGY
  • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
  • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
  • C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
  • C23C8/06—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases
  • C23C8/08—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases only one element being applied
  • C23C8/10—Oxidising
  • C23C8/12—Oxidising using elemental oxygen or ozone
  • C23C8/14—Oxidising of ferrous surfaces
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
  • H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
  • H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M8/00—Fuel cells; Manufacture thereof
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M8/00—Fuel cells; Manufacture thereof
  • H01M8/02—Details
  • H01M8/0202—Collectors; Separators, e.g. bipolar separators; Interconnectors
  • H01M8/0204—Non-porous and characterised by the material
  • H01M8/0206—Metals or alloys
  • H01M8/0208—Alloys
  • H01M8/021—Alloys based on iron
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M8/00—Fuel cells; Manufacture thereof
  • H01M8/10—Fuel cells with solid electrolytes
  • H01M8/12—Fuel cells with solid electrolytes operating at high temperature, e.g. with stabilised ZrO2 electrolyte
  • H01M2008/1293—Fuel cells with solid oxide electrolytes
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M8/00—Fuel cells; Manufacture thereof
  • H01M8/02—Details
  • H01M8/0202—Collectors; Separators, e.g. bipolar separators; Interconnectors
  • H01M8/0204—Non-porous and characterised by the material
  • H01M8/0223—Composites
  • H01M8/0228—Composites in the form of layered or coated products
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
  • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
  • Y02E60/30—Hydrogen technology
  • Y02E60/50—Fuel cells
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
  • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
  • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

• the present disclosure relates to methods for limiting the formation of an electrically resistive surface layer or "scale” on stainless steels when the steels are subjected to high-temperature, oxidizing conditions.
• the present disclosure also relates to stainless steels and articles of manufacture including stainless steels, wherein the steels have a reduced tendency to form electrically resistive scale thereon when the steels are subjected to high-temperature, oxidizing conditions.
• Fuel cells are energy conversion devices that generate electricity and heat by electrochemically combining a gaseous fuel and an oxidizing gas via an ion- conducting electrolyte. Fuel cells convert chemical energy directly into electrical energy in the absence of combustion, providing significantly higher conversion efficiencies than reciprocating engines, gas turbines, and certain other conventional thermomechanical energy production devices. In addition, for the same power output, fuel cells produce substantially less carbon dioxide emissions than fossil fuel-based power generation technologies. Fuel cells also produce negligible amounts of SO x and NO x , the main constituents of acid rain and photochemical smog.
• SOFCs Solid oxide fuel cells
• NASA originally developed alkaline fuel cells including a liquid electrolyte in the 1960's to power Apollo and other spacecraft. Liquid electrolytes, however, typically are corrosive and can be difficult to handle.
• Solid oxide fuel cells in contrast, are constructed entirely of solid-state materials and employ a fast oxygen ion-conducting ceramic material as the electrolyte. SOFCs operate in a temperature range of about 500 0 C-IOOO 0 C to facilitate solid-state transport.
• the advantages of SOFCs include high energy efficiency and relatively few problems with electrolyte management. SOFCs also produce high-grade waste heat, which can be used in combined heat and power devices, and harnessed for internal reforming of hydrocarbon fuels.
• a single SOFC subunit or "cell” includes an anode and a cathode, separated by the electrolyte.
• an oxidant such as oxygen or air
• an oxidant is fed into the fuel cell on the cathode side, where it supplies oxygen ions to the electrolyte by accepting electrons from an external circuit through the following half-cell reaction:
• the oxygen atoms pass through the ceramic electrolyte via solid state diffusion to the electrolyte/anode interface.
• the SOFC can employ hydrogen (H 2 ) and/or carbon monoxide (CO) as a basic fuel. Operationally, pure hydrogen can be used as supplied. If a hydrocarbon fuel such as methane, kerosene, or gasoline is used, it must first be partially combusted, or "reformed", to provide hydrogen and carbon monoxide. This may be accomplished internally within the fuel cell, aided by the high cell operating temperature and by steam injection. The fuel gas mixture penetrates the anode to the anode/electrolyte interface, where it reacts with the oxygen ions from the ion-conducting electrolyte in the following two half-cell reactions:
• PSOFC flat- plate or "planar” SOFC
• a single energy conversion cell 12 includes a cathode 20 and an anode 30 separated by the electrolyte 40.
• An interconnect 50 separates the anode 30 from the cathode 60 of an immediately adjacent energy conversion cell 14 (not fully shown) within the stack.
• PSOFC 10 includes a repeating arrangement of cells, substantially identical to cell 12, with an interconnect disposed between each adjacent cell.
• the interconnects are critical SOFC components and serve several functions, including separating and containing the reactant gases, providing a low resistance current pathway to electrically connect the cells in series, and providing structural support for the stack.
• the interconnects must be made of a material that can withstand the harsh, high-temperature environment within the cells, must remain suitably electrically conductive throughout the fuel cell's service life, and must have a coefficient of thermal expansion (CTE) that is sufficiently similar that of the cells' ceramic components to ensure that the stack's requisite structural integrity and gas- tightness is maintained.
• Initial PSOFC designs utilized LaCrO 3 ceramic interconnects.
• LaCrO 3 ceramic does not degrade at the high SOFC operating temperatures and has a CTE that substantially matches the other ceramic components of the fuel cell.
• LaCrO 3 ceramic is brittle, difficult to fabricate, and expensive.
• interconnects have been made from certain metal alloys.
• Metallic interconnects are desirable for reasons including their relatively low manufacturing cost, high electrical and thermal conductivities, and ease of fabrication, which aids in the formation of gas channels and allows for a high degree of dimensional control.
• Alloys proposed for interconnect applications include nickel-base alloys (such as AL 600TM alloy), certain austenitic stainless steels (such as Types 304, 309, 310 and other alloys in the 300 Series family), and certain ferritic stainless steels (such as, for example, E-BRITE ® alloy and AL 453TM alloy).
• Table 1 provides nominal compositions for several of the foregoing commercially available nickel-base and stainless steel alloys, all of which are available from ATI Allegheny Ludlum, Pittsburgh, Pennsylvania.
• ferritic stainless steels including at least about 16 weight percent chromium make them particularly attractive for PSOFC interconnect applications including, for example, low cost, excellent machinability, and CTEs compatible with conventional ceramic electrodes.
• Ferritic stainless steels including 16-30 weight percent chromium and less than 0.1 weight percent aluminum are believed to be particularly suited for interconnect applications.
• Specific examples of ferritic stainless steels considered suitable for PSOFC interconnect applications include AISI Types 430, 439, 441 , and 444 stainless steels, as well as E-BRITE ® alloy.
• the CTEs of the ceramic electrode material lanthanum strontium manganate and AISI Type 430 ferritic stainless steel, for example, are reported to be about 11-13x10 "6 and about 9-12x10 "6 , respectively.
• Ferritic stainless steels commonly include moderate levels of silicon, either as an intentional alloying addition or as a residual from the steelmaking process. Silicon is commonly present in ferritic stainless steels at levels of about 0.3 to 0.6 weight percent. Silicon is not commonly added to ferritic stainless steels as an intentional compositional element, but it may be added during the melting of stainless steels as a process element. A portion of the silicon added to the melt, however, unavoidably makes its way into the steel. Therefore, even though silicon is intentionally added in such cases, it may be considered a residual impurity in the steel.
• Silicon is detrimental to the operational efficiency of ferritic stainless steel interconnects since it tends to migrate to the steel surface/scale interface and form a thin, generally continuous, highly electrically resistive SiO 2 (silica) layer at the interface.
• SiO 2 silicon
• Formation of silica at the interface between the steel and the scale formed on the steel increases the contact electrical resistivity of the interconnects over time. This makes it increasingly difficult for electrons to pass through the interface region between the interconnect and the electrodes, and thereby progressively impairs the ability of the interconnects to conduct current between the cells.
• This process, over time can significantly reduce the overall efficiency of SOFCs including ferritic stainless steel interconnects. As such, it is one factor considered when selecting a suitable interconnect material from among the various available ceramic and alloy materials.
• One aspect of the present disclosure is directed to a method of reducing the tendency for formation of an electrically resistive silica layer on a silicon- containing ferritic stainless steel article when the article is subjected to high temperature, oxidizing conditions when in service.
• the method includes, prior to placing the article in service, subjecting the article to oxidizing conditions resulting in formation of silica, which includes silicon derived from the steel, on a surface of the steel.
• at least a portion of the silica is removed prior to placing the article in service.
• the conditions under which the silica forms on the steel surface include heating the article in an oxidizing atmosphere at a temperature greater than 600°C for a period of time sufficient to form the silica.
• the ferritic stainless steels that may be included in articles processed by methods according to the present disclosure include any silicon-containing ferritic stainless steel.
• Non-limiting examples of such ferritic stainless steels include silicon- containing AISI Type 430 stainless steel, AISI Type 439 stainless steel, AISI Type 441 stainless steel, AISI Type 444 stainless steel, and E-BRITE ® alloy. Given the present methods' advantages, the methods are considered particularly useful as applied to ferritic stainless steels to be used in SOFC interconnects.
• Another aspect of the present disclosure is directed a method of making a fuel cell interconnect.
• the method includes treating a silicon-containing ferritic stainless steel by subjecting the steel to oxidizing conditions under which silica including silicon derived from the steel forms on a surface of the steel. Optionally, at least a portion of the silica is removed from the surface. The treated steel is subsequently fabricated into the fuel cell interconnect. The method reduces the tendency for formation of an electrically resistive silica layer on the ferritic stainless steel interconnect when the interconnect is subjected to high temperature oxidizing conditions in service.
• Yet another aspect of the present disclosure is directed to an article of manufacture comprising a ferritic stainless steel including at least a near-surface region that has been depleted of silicon relative to a remainder of the ferritic stainless steel.
• a characteristic reduces the tendency for the formation of an electrically resistive silica layer on a surface of the article when the article is subjected to high temperature oxidizing conditions.
• a method according to the present disclosure is applied to the article in order to deplete (Ae., reduce or eliminate) silicon in a near-surface region of the steel.
• the article is a mill product (for example, a sheet, a plate, or a bar) or a fuel cell interconnect.
• Figure 1 is a schematic illustration of an embodiment of a PSOFC.
• Figure 2 is a plot showing the relationship between oxygen partial pressure (right-hand Y axis) and water vapor content (left-hand Y axis, measured as dew point) in hydrogen, and including curves plotting stability limits for various oxides at the indicated range of oxygen partial pressures as a function of temperature.
• Figure 3 is an Auger compositional profile, normalized to measure bulk composition, for a Type 430 stainless steel sample panel annealed in hydrogen for approximately 30 minutes at approximately 1010 0 C.
• Figure 4 is a plot of ASR values (ohm-cm 2 ) obtained at 700 0 C and 800 0 C testing temperatures for several ferritic stainless steel samples prepared as described herein.
• Figure 5 is a plot of ASR values (ohm-cm 2 ) obtained at a 800°C test temperature in air for various steel-ceramic-steel "sandwich" assemblies monitored over 500 hours.
• Figure 6 is a plot of weight change (mg/cm 2 ) over time for various treated and untreated ferritic stainless steel samples heated in a simulated anode gas.
• ferritic stainless steels commonly include moderate amounts of silicon, either as an intentional alloy addition or as a residual impurity.
• silicon can readily diffuse to the alloy/scale interface and form a thin, generally continuous, electrically resistive SiO 2 (silica) film.
• SiO 2 silicon oxide
• the tendency for silicon segregation and oxidation is high and has been observed to occur in alloys including even very low levels of silicon. This phenomenon can impair the surface electrical conductivity of ferritic stainless steel interconnects and significantly decrease fuel cell efficiency over time.
• the present disclosure in part, is directed to a method for eliminating or reducing the tendency for formation of electrically resistive silica on the surface of ferritic stainless steels. More particularly, the present disclosure describes unique methods for reducing the formation of an electrically resistive silica layer on the surface of ferritic stainless steel articles when the articles are subjected to the high-temperature oxidizing conditions typically found within SOFCs, conditions to which interconnects are commonly subjected. Such a method involves treating the article to induce formation of silica on a surface of the steel. Optionally, at least a portion of the silica is removed from the surface using a suitable silica removal technique.
• the article may then, optionally, be further processed to a suitable form, and subsequently placed in service.
• the method alters the silicon content of at least a sub-surface region of the steel so as to inhibit formation of silica when the treated article is subjected to high-temperature oxidizing conditions in service.
• At least a portion of the silicon in a silicon-containing ferritic stainless steel article is segregated to a surface of the article and oxidized on the surface by "pre-oxidizing" the article for a suitable time in a suitable oxidizing atmosphere.
• article refers to either a mill product such as, for example, a sheet, a plate, or a bar, and also refers to a finished article of manufacture produced by further processing the mill product to an intermediate or final form.
• oxidizing atmosphere refers to an atmosphere and/or other conditions promoting the formation of oxides on the surface of a ferritic stainless steel article subjected to the atmosphere and/or conditions for a suitable period of time.
• Embodiments of the methods according to the present disclosure may be applied to any silicon-containing ferritic stainless steel.
• Methods according to the present disclosure are considered particularly advantageous when applied to ferritic stainless steel including relatively high levels of silicon such as, for example, at least 0.15 weight percent silicon, but may be applied to any silicon-containing ferritic stainless steel.
• ferritic stainless steels comprising, in weight percentages: 15 to 30 chromium; up to 6 molybdenum; up to 2 manganese; up to 1 nickel; up to 1 silicon; up to 1 aluminum; up to 0.1 carbon; up to 0.1 nitrogen; up to 1 titanium; up to 1 niobium; up to 1 zirconium; up to 1 vanadium; iron; and incidental impurities.
• Non-limiting examples of suitable oxidizing atmospheres that can be used in the pre-oxidizing step include an atmosphere at a suitable oxidizing temperature principally including hydrogen along with a relatively small concentration of oxygen.
• suitable oxidizing atmospheres include cracked ammonia or synthetic ammonia, argon or another inert gas or mixture of inert gases, and nitrogen, all of which atmospheres also must include a low concentration of oxygen sufficient to suitably oxidize silicon segregated to the alloy surface.
• An atmosphere including a large nitrogen concentration may promote nitridation at high temperatures and, thus, is not preferred.
• the concentration of oxygen in the oxidizing atmosphere is such that the atmosphere selectively oxidizes silicon on a surface of the article, while not resulting in the formation on the surface of a significant level of oxides derived from other elements within the stainless steel.
• One embodiment of a method according to the present disclosure includes annealing (heating) the ferritic stainless steel article in an oxidizing atmosphere at a temperature similar to, or preferably in excess of, the temperature range to which it is expected the steel will be subjected while in service. In this way it is possible to significantly deplete silicon within a sub-surface region of the steel and thereby reduce the amount of silica formed on surfaces of the article when the article is subjected to high temperature oxidizing conditions in service. More preferably, the annealing treatment is performed at a temperature that is at least 100 0 C greater, and even more preferably at least 200 0 C greater, than the temperature to which the article will be subjected when in service.
• the annealing is preferably conducted at a temperature in the range of at least 600 0 C up to about 1100 0 C, and more preferably is conducted at a temperature that is considerably higher (for example, at least 100 0 C or at least 200 0 C higher) than the conventional 700-800 0 C operating temperature that is common for SOFCs.
• exposing a ferritic stainless steel article to a partially oxidizing hydrogen-containing atmosphere, preferably including up to about 1 x 10 ⁇ 20 atmosphere of oxygen, at a suitably elevated temperature and for a suitable duration results in the formation of silica on the article's surfaces.
• the silicon for formation of the oxides migrates by solid state diffusion from the bulk of the alloy.
• the silica layer formed on the steel surface has a thickness of at least 0.5 microns per millimeter thickness of the steel.
• all or a portion of the silica formed during the oxidizing treatment is removed using a suitable silica removal technique prior to placing the steel in service.
• a suitable silica removal technique include mechanical, chemical, and thermochemical techniques capable of removing silica from the surface of a ferritic stainless steel, preferably without also removing a significant amount of the steel underlying the silica. More preferably, the silica removal technique applied to the steel will not remove any of the steel underlying the silica to be removed.
• Non-limiting examples of possible mechanical silica removal techniques include mechanical abrasion techniques such as, for example, sanding and grinding.
• Non-limiting examples of possible chemical silica removal techniques include immersing the article in, or applying to the article surface, a caustic or acidic liquid that dissolves silica.
• Non-limiting examples of possible thermochemical silica removal techniques include immersing the article in, or applying to the article surface, a caustic or acidic liquid that dissolves silica and that is maintained at an elevated temperature suitable to enhance the rate of dissolution of silica.
• Those of ordinary skill may readily recognize other suitable techniques for removing all or a portion of silica formed on a surface of the steel.
• the step of "pre-oxidizing" the article utilizes the driving force of oxide formation to segregate at least a portion of the silicon within the steel to a surface of the steel. It is known that low-oxygen atmospheres such as, for example, dry hydrogen atmospheres, remain oxidizing to silicon and certain other alloy ingredients that have solid state mobility and an extremely high affinity for oxygen.
• the oxygen content of hydrogen is generally determined by assessing the residual water vapor content of the gas since oxygen and water are related through the well known water shift reaction:
• Figure 2 is a plot showing the relationship between oxygen partial pressure (right-hand Y-axis) and water vapor content (left-hand Y-axis, measured as dew point) in hydrogen. As suggested by the above water shift reaction, as the water vapor content of a gas increases, the oxygen partial pressure within the gas also increases. Figure 2 also includes curves plotting stability limits for various oxides, at the indicated range of oxygen partial pressures, as a function of temperature.
• the present inventor concluded that these principles can be applied to ferritic stainless steels to selectively promote silicon migration/segregation and oxidation without significantly promoting migration/segregation and oxidation of chromium and various other alloying elements within the steels.
• the oxygen partial pressure in the oxidizing atmosphere used in the methods according to the present disclosure preferably is below, and more preferably is just below, the oxygen partial pressure at which oxides of chromium are stable and will form on the steel.
• the oxygen partial pressure may be up to about 1 x 10 "20 atmosphere.
• certain embodiments of methods according to the present disclosure promote formation of silica on surfaces of silicon-containing ferritic stainless steel and thereby result in significant depletion of the silicon in at least a near-surface region of the alloy, preventing or reducing the tendency for silica to form on surfaces of the steel when later subjected to high temperature oxidizing conditions in service.
• the dew point of the hydrogen atmosphere was not measured but was believed to be in the range of about -20 0 C to 0 0 C.
• the panel was heated in the furnace chamber at approximately 1010 0 C for 30 minutes time-at- temperature (as measured by a contact thermocouple).
• the sample panel emerged from the furnace after heating with a dull surface tint, indicating that a relatively thick silica-containing layer (scale) had formed on the panel surface.
• Figure 3 illustrates the Auger compositional depth profile of the stainless steel sample, normalized to measure bulk composition.
• Figure 3 plots relative enrichment of iron, silicon, and chromium in the oxide layer at various depths. Significant segregation of silicon from the alloy bulk to the alloy surface was detected, with an approximately 0.18 micron (180 nm) thick silica layer evident on the surface.
• the scale/alloy interface i.e., the original surface of the steel, which was at about 0.18 micron measured from the surface of the scale, is indicated by the vertical line at about the mid-point of Figure 3.
• Figure 3 also shows that only very minor segregation of chromium toward the scale surface occurred as the silica-containing layer formed. Figure 3 further indicates that no evident segregation of iron occurred during oxide formation.
• the trial confirmed that selective migration of silicon from the alloy bulk and pre-oxidation of the silicon on the alloy surface is a viable method of selectively depleting at least a portion of silicon within the alloy.
• the steel After formation of the silica layer on the test panel, small coupons were cut from the panel. Several of the coupons were left as-oxidized. Other coupons were subjected to a post-oxidation treatment to remove all or a portion of the oxide scale.
• the scale removal treatments used were (i) immersion of the coupon in 0.1 M hydrofluoric acid for about 2 minutes and (ii) immersion of the coupon in 1 M sodium hydroxide at about 60 0 C for about 30 minutes. It is believed that the acid treatment would remove bulk alloy along with the scale if the coupon were immersed for a sufficient time period.
• the steel preferably is subjected to relatively aggressive removal treatments, such as hydrofluoric acid solutions, for a relatively limited duration in order to avoid removal of silicon-depleted near-surface alloy.
• the particular base treatment used should leave unaffected the underlying alloy substrate and, thus, the exposure time may be relatively liberal.
• ASR area specific resistivity
• Figure 4 is a plot of ASR values (ohm-cm 2 ) obtained at the 700 0 C and 800 0 C testing temperatures (spanning the typical SOFC operating temperature range) for the foregoing samples as follows: (1 ) samples of Type 430 stainless steel that were not subjected to pre-oxidation treatment ("430 Control-1 " in Figure 4); (2) as-oxidized samples, which were pre-oxidized as discussed above but were not subjected to further processing to remove the resulting oxide scale ("H2"); (3) samples that were pre-oxidized, immersed in hydrofluoric acid solution to remove all or a portion of the scale, and then oxidized at 800°C, as discussed above (“H2-acid”); and (4) samples that were pre-oxidized, immersed in sodium hydroxide solution, and then oxidized at 800 0 C, as discussed above (“H2-NaOH").
• Figure 4 shows that the method including pre-oxidation and oxide scale removal steps is relatively effective at limiting contact resistance as evaluated at 700 0 C, and is even more effective as evaluated at 800°C.
• ASR reductions achieved by application of embodiments of methods according to the present disclosure ranged the from approximately 50% when evaluated at 700 0 C, to approximately 75% when evaluated at 800°C. Silicon was actually removed from the alloy by the techniques applied, and it is likely that silicon mobility within the alloy is greater at 800 0 C and would cause greater problems in terms of increased electrical resistivity if not depleted from at least the near-surface region before the alloy is placed in service.
• Figure 4 shows that the treated samples (2, 3 and 4) had lower ASR values at each test temperature than the untreated samples (1 ). Of the pre-oxidized samples (2, 3 and 4), the acid-cleaned samples (3) exhibited the worst ASR values at both test temperatures. Without intending to be bound by any particular theory of operation, it is believed that at least a portion of the beneficial silicon-depleted region beneath the oxide scale of the sample was removed along with the oxide scale by the acid cleaning treatment applied in the testing, allowing for a relatively short path of migration of silicon from the bulk of the alloy.
• Uncoated pre-oxidized samples, MC coated pre-oxidized samples, and MC coated untreated samples were tested by placing test samples of the same type on either side of a thin block of lanthanum strontium manganate (LSM) ceramic.
• LSM lanthanum strontium manganate
• a thin layer of LSM ink was painted on the contacting faces to better ensure intimate contact between the samples and the LSM ceramic.
• An electrical current was impressed across the steel-LSM-steel "sandwich” using a power supply, and the resulting voltage established between the steel samples, across the ceramic, was measured. The voltage was converted to area specific resistivity (ASR) and reported in mohm-cm 2 , which is a normalized measure of the relative ease or difficulty of electrical current to move across the sandwich.
• ASR area specific resistivity
• a lower ASR is desirable as it equates to lower contact electrical resistivity between the steel samples and the ceramic.
• the fuel cell output decreases and, therefore, the energy generation process becomes less efficient.
• the fuel cell eventually may stop generating electric current. Therefore, it is desirable to use materials in fuel cell interconnects with an ASR that is initially low and increases at a very slow rate.
• FIG. 5 graphically depicts the results of heating the sandwiches in the high-temperature oxidizing test environment.
• a temporary power loss and the re-equilibration of the test set-up at 165 hours resulted in a gap and discontinuity in each curve of Figure 5 at that time.
• Data losses during the periods of approximately 245-315 hours and 405-445 hours also produced gaps in the curves of Figure 5.
• Figure 5 clearly shows that sandwiches including the MC coated pre-oxidized samples had a significantly lower ASR over the test period when heated in the oxidizing test atmosphere.
• Coupons of the following ferritic stainless steels used in interconnect applications were prepared: AISI Type 430 (UNS S43000); Type 439 (UNS S43035); Type 441 (UNS S44100); and E-BRITE ® alloy (UNS S44627). Coupons of Types 430, 439, and 441 were pre-oxidized to remove silicon from sub-surface regions of the coupons using the technique described above in Example 2 (i.e., 1010 0 C for 30 minutes). Other coupons were left untreated. The coupons were then heated at 800 0 C in simulated anode gas (SAG) for a time in excess of 1000 hours, and the normalized weight change (mg/cm 2 ) of each sample was determined periodically.
• SAG simulated anode gas
• the SAG consisted of 4 vol.% hydrogen, 3 vol.% water vapor, and balance argon, and simulated the fuel side environment within a SOFC. The oxygen content within the SAG was low, but sufficient to oxidize the samples.
• Figure 6 is a plot of the test results.
• Pre-oxidation i.e., desiliconiz- ation
• the results confirm that the pre-oxidation treatment according to the present disclosure for removing silicon from subsurface regions of ferritic stainless steels reduces the rate of oxidation of the pre-oxidized steels when subjected to environments simulating those to which an interconnect is subjected within a SOFC.
• FIG. 6 shows that E-BRITE ® alloy in the untreated state exhibited the lowest weight change of any of the test samples.
• E-BRITE ® alloy is a more costly material given that, for example, it includes at least about 10 weight percent more chromium than the other ferritic stainless steels tested. In any case, it is expected that pre-oxidizing E-BRITE ® alloy samples using the technique applied to the other samples would have resulted in a reduced weight gain relative to the untreated E-BRITE ® alloy samples.
• embodiments of methods according to the present disclosure involve subjecting an article (such as, for example, a mill product, an interconnect, or another part) composed of a silicon-containing ferritic stainless steel to a pre-oxidation treatment adapted to promote formation of an external surface oxide layer including silica derived from silicon present in the steel.
• All or a portion of the silica-containing oxide scale may be removed by a suitable silica removal technique such as, for example, a suitable mechanical, chemical, or thermochemical technique.
• suitable silica removal technique such as, for example, a suitable mechanical, chemical, or thermochemical technique.
• Non-limiting examples of chemical scale removal techniques, discussed above include applying an acid or caustic liquid to the scale. It may be advantageous to heat the liquid in order to speed dissolution of the scale within the liquid and, thus, a thermochemical technique (involving a heated chemical) may be preferable to a immersion in a room- temperature liquid bath.
• the pre-oxidizing treatment serves to deplete silicon from at least a portion of the substrate, primarily near the steel surface, which in turn decreases the tendency for silica formation on the surface of the substrate when subjected to subsequent elevated temperature or other oxidizing conditions. Removing all or a portion of the silica scale appears to be beneficial in terms of better inhibiting formation of silica when the treated surface is later subjected to oxidizing conditions in service. Nevertheless, methods according to the present disclosure also appear to inhibit in- service silica formation even if the silica formed on the steel during pre-oxidation step is not removed.

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