Investigation of the synthesis and internal structure of protective oxide layers on high-purity chromium with SIMS scanning techniques

The major problem affecting the application of chromium in high temperature processes is the ongoing spallation of the protective oxide layer formed during hot-gas oxidation. This results in a continuous material erosion. To gain a deeper insight in the spallation and oxidation process, a high-purity powder-metallurgically produced chromium sample was submitted to a two-stage hot gas oxidation process. The formed oxide layers were investigated by 3D SIMS and scanning SIMS. The formation of the protective oxide layer is carried by the diffusion of chromium from the bulk through the already existing oxide layer and the reaction of the diffused chromium with the oxygen from the gaseous phase. In parallel to the growing of the oxide layer, an accumulation of impurities at the interface oxide layer – bulk can be observed. The enrichment of trace elements at the interface level (for the investigated sample Cl and N) can be explained by the low solubility of these elements in chromium oxide and therefore their inability to diffuse through the already formed protective layer. Received: 24 June 1996 / Revised: 22 January 1997 / Accepted: 26 January 1997     

In Situ Study of the Surface Oxidation of FeCr Alloys Using Grazing Incidence X‐ray Absorption Spectroscopy (GIXAS)

The surface oxidation of FeCr alloys with 18, 28, and 43 mass‐% Cr was investigated in situ using grazing‐incidence X‐ray absorption spectroscopy (GIXAS) at the chromium and iron K‐edges. Oxidation in air was monitored in situ in the temperature range from 290 K to 680 K. The standard GIXAS data analysis is extended for the treatment of a single layer model in order to estimate the chromium concentrations of the oxide layer and of the near‐interface substrate as well as the oxide layer thickness. XANES analysis shows transitions from b.c.c. Fe to corundum type Fe₂O₃ and from b.c.c. Cr to corundum type Cr₂O₃. The initial oxide layers are 1.1‐1.4 nm thick and contain 60‐90 mass‐% chromium, while the near‐interface substrate is depleted in Cr. During heating, iron oxide growth dominates up to 560‐600 K. Then the chromium oxide layer loses its passivation effect and Cr oxidation sets in.     

SIMS investigations on the growth mechanisms of protective chromia and alumina surface scales

The oxidation behaviour of the oxide-dispersion strengthened (ODS) high-temperature alloys MA 956 (an aluminium oxide former) and MA 754 (a chromium oxide former) has been compared with that of two model alloys, Fe-20Cr-5Al and Ni-25Cr. The morphology and composition of the oxide scales were investigated by metallography, X-ray diffraction analysis and scanning electron microscopy. For analysis of the oxide layer growth mechanisms, twostage oxidation experiments with¹⁸O as tracer were used, the distribution of the oxygen isotopes in the oxide scale being determined by SIMS. The ODS alloys show a more selective oxidation than the two model alloys; moreover, the protective oxides on the ODS alloys have a lower growth rate and better adhesion than those on the two model alloys. From the SIMS investigations it can be deduced that the improved properties of the layers on the ODS alloys result from a change in the transport processes in the protective layer; whereas the aluminium and chromium oxide films on the conventional alloys grow by cation and anion transport, the scales on the ODS alloys grow almost exclusively by anion transport. It is shown that the observed properties of the oxide scales on the ODS alloys can be explained by this change in transport mechanism.Dedicated to Professor Günther Tölg on the occasion of his 60th birthday     

Surface analysis of nitride layers formed on Fe‐based alloys through plasma nitride process

Nitriding phenomena that occur on the surfaces of pure Fe and Fe? Cr alloy (16 wt% Cr) samples were investigated. An Ar + N₂ mixture‐gas glow‐discharge plasma was used so that surface nitriding could occur on a clean surface etched by Ar⁺ ion sputtering. In addition, the metal substrates were kept at a low temperature to suppress the diffusion of nitrogen. These plasma‐nitriding conditions enabled us to characterize the surface reaction between nitrogen radicals and the metal substrates. The emission characteristics of the band heads of the nitrogen molecule ion (N₂⁺) and nitrogen molecule from the glow‐discharge plasma suggest that the active nitrogen molecule is probably the major nitriding reactant. AES and angle‐resolved XPS were used to characterize the thickness of the nitride layer and the concentration of elements and chemical species in the nitride layer. The thickness of the nitride layer did not depend on the metal substrate type. An oxide layer with a thickness of a few nanometers was formed on the top of the nitride layer during the nitriding process. The oxide layer consisted of several species of N_x‐Fe_y‐O, NO⁺, and NO₂^?. In the Fe? Cr alloy sample, these oxide species could be reduced because chromium is preferentially nitrided. Copyright © 2009 John Wiley & Sons, Ltd.     

Computational insights into the molecular mechanisms for chromium passivation of stainless-steel surfaces

First principles DFT calculations are used to gain insights into the molecular mechanism of Cr passivation of FeCr alloy surfaces. The systems studied represent early stages of oxidation of FeCr alloys when the oxide layers extend just a few atomic layers into the bulk. A Monte-Carlo atom-swapping algorithm was developed to efficiently explore possible atomic positions and identify the most promising structures that yield overall energy lowering. Analysis of the resulting low energy structures show that the surface oxide layer is rich in chromium while there is a reduction in chromium in the metallic phase near the alloy-oxide interface. Furthermore, there is an increased concentration of Fe near the oxide-air surface. Analysis of the molecular structure of the oxide layers found that oxidized Cr was predominantly in the Cr₂O₃ phase, while oxidized Fe was present as both FeO and Fe₂O₃. We propose that the oxidative variability of Fe facilitates O diffusion in the iron-rich phases because of the range of geometries available for accommodating the O atom. In contrast, O diffusion is less facile in Cr, which has little variability in oxidation state.     

Oxide density distribution across the barrier layer during the steady state growth of porous anodic alumina films: chronopotentiometry, kinetics of mass and thickness evolution and a high field ionic migration model

The steady state growth of porous anodic alumina films in oxalate solutions at various conditions was studied by chronopotentiometry, mass balance and optical microscopy methods enabling determination of consumed Al, film mass and thickness, current efficiencies, Al³⁺ and O²⁻ transport numbers across barrier layer, etc. The film thickness growth rate was found to be proportional to O²⁻ anionic current. A high field ionic migration model was developed. It predicted that, during anodising, the local oxide density across barrier layer rises from 2.6 in Al|oxide to 4.59–5.22 g cm⁻³ in oxide|electrolyte interface with mean value ≈3.21–3.52 g cm⁻³. The field strength rises from the first to second interface. The mechanism of Al oxidation near the Al|oxide interface embraces the transformation of the Al lattice to a transient, rare oxide one sustained by field with comparable Al³⁺ spacing parameter. The oxide near the Al|oxide interface and around the density maximum in the oxide|electrolyte interface are under different levels of electro-restriction stresses. During relaxation, the oxide behaves like a solid-fluid material suppressing the initial density distribution.     

AES- und XPS-Untersuchungen zum Einflu? von Chrom, Nickel und Molybd?n auf das Korrosionsverhalten von rostfreien St?hlen in S?uren

Summary The alloys Fe17.8Cr, Fe16Cr2.4Mo and Fe18Cr14Ni2.5Mo (at%) were polarized in 0.5 mol/l H₂SO₄ or in 0.1 mol/l HC1 + 0.4 mol/l NaCl. The composition of the oxide layer and of the metallic layer beneath the oxide and the kinetics of the passive layer formation were determined by AES and XPS. In the active region, selective dissolution of Fe leads to an enrichment of Cr, Ni and Mo at the metal/electrolyte interface. In the passive region, the thickness of the rapidly formed passive layer is determined by the potential. The chromium content of the passive layer approaches a stationary, high value. The passive layer essentially consists of the anions O^2- and OH^– and of the cations of Cr, Fe, Mo, whereas Ni — and less pronounced Mo — are enriched below the layer.     

TEM and SNMS studies of protective alumina scales on NiCrAlY-alloys

The effect of Si addition on the oxidation behaviour of NiCrAlY alloys in the temperature range 950 bis 1100° C has been investigated. During isothermal oxidation oxide growth rates were practically independent of the Si-content. However during cyclic oxidation Si additions were beneficial. Si additions of 1–2^m/₀ appeared to shift the onset for spallation to longer times. It was found that Si stabilizes the -phase and probably it suppresses the formation of metastable Al₂O₃ modifications.     

Thermal behaviour of chromium (III) perchlorate hexahydrate

Thermal behaviour of intimate mixtures of chromium(III) oxide and lithium¹, potassium², rubidium³, cesium³ and thallium(I)⁴ perchlorates revealed that chromium(III) oxide not only catalyses the decomposition by lowering the decomposition temperatures of the pure metal perchlorates but also chemically interacts resulting in the formation of metal dichromate. The oxidation of chromium(III) into the hexavalent state is attributed to the abstraction of oxygen from the perchlorate moiety during the decomposition. In this context, it was thought interesting to study the thermal behaviour of chromium(III) perchlorate and to identify the decomposition products in order to find out whether chromium(III) is oxidized into chromium(VI) by the perchlorate group. Except for a report⁵ on the preparation of chromium(III) perchlorate with different molecules of water of hydration no work seems to have been carried out on the thermal decomposition of this compound. In the present study, the decomposition characteristics are followed by TG and DTA techniques and the decomposition products have been examined by chemical analysis, X-ray powder diffraction patterns and infrared spectral measurements.     

Electrochemical Oxidation of Nitrogen towards Direct Nitrate Production on Spinel Oxides

Nitrates are widely used as fertilizer and oxidizing agents. Commercial nitrate production from nitrogen involves high‐temperature‐high‐pressure multi‐step processes. Therefore, an alternative nitrate production method under ambient environment is of importance. Herein, an electrochemical nitrogen oxidation reaction (NOR) approach is developed to produce nitrate catalyzed by ZnFe_xCo_2?xO₄ spinel oxides. Theoretical and experimental results show Fe aids the formation of the first N?O bond on the *N site, while high oxidation state Co assists in stabilizing the absorbed OH^? for the generation of the second and third N?O bonds. Owing to the concerted catalysis, the ZnFe_0.4Co_1.6O₄ oxide demonstrates the highest nitrate production rate of 130±12 μmol h^?1 g_MO^?1 at an applied potential of 1.6 V versus the reversible hydrogen electrode (RHE).     

Vanadium Nitride Films Formed by Rapid Thermal Processing (RTP): Depth Profiles and Interface Reactions Studied by Complementary Analytical Techniques

The nitridation of vanadium films in molecular nitrogen and ammonia using a RTP‐system was investigated. The V films were deposited on silicon substrates covered by 100 nm thermal SiO₂. For a few experiments sapphire substrates were used. Nitride formation at high temperatures (900 and 1100 °C) and interface reactions and diffusion of oxygen out of the SiO₂‐layer into the metal lattice at moderate temperatures (600 and 700 °C) were studied. For characterisation complementary analytical methods were used: X‐ray diffraction (XRD) for phase analysis, secondary neutral mass spectrometry (SNMS) and Rutherford Backscattering (RBS) for acquisition of depth profiles of V, N, O, C and Si, transmission electron microscopy (TEM) in combination with electron energy filtering for imaging element distributions (EFTEM) and recording electron energy loss spectra (EELS) to obtain detailed information about the initial stages of nitride, oxide and oxynitride formation, respectively, and the microstructure and element distributions of the films. In these experiments the SiO₂‐layer acts as diffusion barrier for nitrogen and source for oxygen causing the formation of substoichiometric vanadium oxides and oxynitrides near the V/SiO₂‐interface primarily at temperatures ≤ 900 °C. At a temperature of 1100 °C just a small amount of oxynitride forms near the interface because rapid diffusion of nitrogen and fast formation of VN (diffusion barrier for oxygen) inhibit the outdiffusion of oxygen into the metal layer. In the 600 °C regime, in argon atmosphere oxynitride phases observed in the surface region of these films originate from reaction of residual oxygen in the argon gas, whereas NH₃ as process gas does not lead to oxide or oxynitride formation at the surface (apart from the oxidation caused by storage). NH₃ seems to support the diffusion of oxygen out of the SiO₂‐layer. During the decomposition of ammonia at higher temperatures hydrogen is formed, which could attack the SiO₂. In contrast, sapphire substrates do not act as oxygen source in the 600 °C regime and change the nitridation behaviour of the vanadium films.     

Effect of the reaction medium on the physicochemical properties of the oxide monolith catalyst IK-42-1 for ammonia oxidation

The changes in the properties of the oxide monolith catalyst IK-42-1 for ammonia oxidation upon 3540-h-long operation as the second stage of a UKL-7 industrial reactor were studied by X-ray diffraction, chemical analysis, secondary ion mass spectrometry, temperature-programmed reduction, and IR spectroscopy. The spent catalyst shows a lower activity and a lower nitrogen oxide selectivity than the initial catalyst: the decrease in the NO yield is about 25%. As the catalyst operates, the state of its surface changes under the action of the reaction medium. The specific surface area of the catalyst decreases, and the total pore volume increases, which can cause a slight decrease in the ammonia conversion and diminish the mechanical strength of the monoliths. Under the ammonia oxidation conditions, there can be partial reduction of the catalyst surface and the local formation of a spinel structure (spinel-like defects). Oxygen adsorbed on these areas/defects is characterized by a high activation energy of desorption, which favors the reaction route yielding molecular nitrogen. According to IR spectroscopic data, the spent catalyst has a lower concentration of active, coordinatively unsaturated Fe²⁺ sites of adsorption, which are responsible for ammonia oxidation into NO. The decrease in the number of active sites can be due to both the breakdown of the solid solution of iron oxide in aluminum oxide during the reaction and the blocking of these sites by silicon, alkali and alkaline-earth metal, chromium, and rhodium atoms present on the surface of the spent catalyst.     

Characterization and Catalytic Properties of Aerogel Chromium Oxide Supported by Alumina or Silica

Alumina or silica supported chromium oxide catalysts prepared by sol-gel technique have been investigated by X-ray diffraction, BET analysis, combined diffuse reflectance spectroscopy, EPR and reduction-extraction by ethane 1,2 diol. The results reveal the presence of Cr³⁺, Cr⁵⁺ and Cr⁶⁺ ions. Chromium species Cr⁶⁺ are isolated and atomically dispersed on the alumina support as free chromate CrO ₄ ^2– while on silica, dichromate or polychromate species like Cr₂O ₇ ^2– or Cr₃O ₁₀ ^2– predominate. Chromium oxide exhibits a better catalytic properties for paraxylene partial oxidation, when it is supported on alumina. The difference of oxidation states and degree of oligomerisation of chromium on the two supports affects the catalytic properties.     

原位XPS技术研究碳化铀的表面氧化

采用X射线光电子能谱(XPS)原位分析研究了298 K时烧结UC的清洁表面在O₂气氛中的初始氧化过程. UC试样清洁表面通过氩离子束长时间溅射获取. 初始反应各阶段U4f, O1s和C1s芯能级谱的变化显示样品表面的氧化产物为UO₂和自由碳. 当O₂饱和吸附后, UC表面氧化膜的增长呈抛物线型, 氧透过氧化膜的扩散为UC进一步氧化的速率控制步骤. 定量分析表明, 反应过程中U, C原子均未出现明显的表面偏析.     

New approaches to the preparation of highly efficient chromium-containing oxide catalysts for the water gas shift reaction

It was found experimentally that the solutions of Cr³⁺ nitrate and the nitrates of other metals that are the constituents of Cr-containing catalysts can be prepared by dissolving a corresponding metal (for example, cast iron and electrolytic copper) in a solution of chromic anhydride and nitric acid to reach the quantitative reduction of Cr⁶⁺ without the formation of nitrogen oxides. Analogously, the oxidation of Fe²⁺ cations to Fe³⁺ coupled with the reduction of hexavalent chromium can be performed. The precipitation of Fe³⁺, Cr³⁺, and Cu²⁺ ions at a ratio of Fe: Cr = 9 and a concentration of Cu²⁺ to 20 at % can result in the formation of a partially hydrated oxide with the hydrohematite structure—a dispersed and highly defective oxide structure with a high specific surface area more than 300 m²/g and a higher thermal stability, as compared with the goethite phase (α-FeOOH). The dehydration of hydrohematite occurred at a noticeable rate at temperatures higher than 400°C. Hydrohematite promoted with copper cations exhibited high activity below 400°C; this can decrease the starting temperature of the adiabatic high-temperature WGSR to 300°C or below.     

Anodic silver (II) oxides investigated by combined electrochemistry,ex situ XPS and in situ X‐ray absorption spectroscopy

Silver (II) oxide layers (AgO) were prepared by anodic oxidation of pre‐oxidized, Ag₂O‐covered silver electrodes in 1 M NaOH (pH 13.8). The oxidized electrodes were investigated using a combination of electrochemical techniques, ex situ X‐ray photoelectron spectroscopy (XPS) and in situ surface‐sensitive grazing incidence X‐ray absorption spectroscopy (EXAFS) under full potential control. The application of these different techniques leads to a detailed, consistent picture of the anodic silver (II) oxide layer formation. The experiments have shown that the chemical composition of the AgO layer varies significantly with oxidation potential, revealing a decreasing oxygen deficiency with increasing anodization potential and oxidation time. XPS as well as EXAFS experiments support the interpretation of the oxide as a mixed valence Ag ⁺ Ag^{3 +} O₂ with different contributions of Ag ⁺ and Ag^{3 +} species, depending on potential and anodization time. Copyright © 2009 John Wiley & Sons, Ltd.     

Characterization of the Corrosion of Nanostructured 17-4 PH Stainless Steel by Surface Mechanical Attrition Treatment (SMAT)

Abstract

The corrosion properties of nanostructured 17-4PH stainless steel facilitated by a surface mechanical attrition treatment (SMAT) process were studied using electrochemical measurements in 0.6?M NaCl aqueous solution. The microstructure of the surface layer was characterized by X-ray diffraction (XRD) and scanning electron microscopy (SEM). The results demonstrated the formation of a nanostructured surface layer on the surface of the material. By the combination of SMAT and low-temperature annealing processes, the potentiodynamic polarization measurements and X-ray photoelectron spectroscopy (XPS) spectra demonstrated an improvement in the corrosion resistance of 17-4PH stainless steel with a reduced corrosion current density of 0.241?mA/cm² and a higher chromium content. The improved corrosion resistance may be attributed to the formation of nucleation sites through which chromium may freely move from the matrix to the upper surface and thereby form a protective oxide layer on the surface of the material.     

TEM and SNMS studies of protective alumina scales on NiCrAlY-alloys

The effect of Si addition on the oxidation behaviour of NiCrAlY alloys in the temperature range 950 bis 1100 degrees C has been investigated. During isothermal oxidation oxide growth rates were practically independent of the Si-content. However during cyclic oxidation Si additions were beneficial. Si additions of 1-2(m)/(0) appeared to shift the onset for spallation to longer times. It was found that Si stabilizes the beta-phase and probably it suppresses the formation of metastable Al(2)O(3) modifications.     

Synthesis of LPPE by gas-phase copolymerization of ethylene with 1-butene: A highly efficient chromium oxide supported catalyst

A modified chromium oxide supported catalyst has been developed and applied in industry for the manufacture of LPPE via the gas-phase (co)polymerization of ethylene. The catalyst contains surface chromium oxide in the oxidation number Cr²⁺, two modifiers (aluminum oxide and fluorine surface compounds), and silicon dioxide as a support. The activity of the new chromium oxide catalyst in the gas-phase copolymerization of ethylene with 1-butene is higher by a factor of 4–5 than that of the traditional commercial catalytic system based on the supported bis(triphenylsilylchromate) catalyst. An increased reactivity of 1-butene in its copolymerization with ethylene in the presence of the chromium oxide catalyst makes it possible to reduce the consumption of 1-butene in the synthesis of a linear medium-density PE (0.937–0.938 g/cm³). Gas pipes made of PE prepared with the new catalyst are characterized by improved resistance to crack propagation.     

XPS spectroscopic study of potentiostatic and galvanostatic oxidation of Pt electrodes in H2SO4 and HClO4

The surface oxides produced from potentiostatic and galvanostatic oxidation of Pt electrodes in HClO₄ and H₂SO₄ are examined using X-ray photoelectron spectroscopy. The oxide I species produced as the initial oxidation product by successively more anodic potentiostatic oxidation in 0.2 M HClO₄ is found to have a Pt²⁺ oxidation state, a binding energy characteristic of neither PtO, Pt(OH)₂ or PtO₂, and a limiting thickness of 8 Å. Galvanostatic oxidation in HClO₄ and H₂SO₄ is found to produce PtO₂·H₂O as an unlimiting growth oxide or a limiting growth oxide layer depending on the concentration of the acid electrolyte. The incorporation of the acid electrolyte anion in the surface layer is shown to have an effect on which type of oxide layer is produced. X-ray decomposition and chemical modification by Ar⁺ stripping are shown to produce chemical artifacts complicating any interpretation of a Pt oxide surface layer.