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Unveiling the atomistic mechanism of oxide scale spalling in heat-resistant alloys

Author

Listed:
  • Congcong Li

    (University of Science and Technology Beijing
    Liaoning Academy of Materials)

  • Wenjin Zheng

    (Fuzhou University)

  • Haonan Zhong

    (University of Science and Technology Beijing)

  • Xiongjun Liu

    (University of Science and Technology Beijing
    Liaoning Academy of Materials)

  • Huihui Zhu

    (University of Science and Technology Beijing)

  • Hui Wang

    (University of Science and Technology Beijing)

  • Yuan Wu

    (University of Science and Technology Beijing
    Liaoning Academy of Materials)

  • Xiaobin Zhang

    (University of Science and Technology Beijing)

  • Zhiyang Yu

    (Fuzhou University)

  • Suihe Jiang

    (University of Science and Technology Beijing
    Liaoning Academy of Materials)

  • Zhaoping Lu

    (University of Science and Technology Beijing)

Abstract

An intact oxide scale adhering well to the matrix is crucial for the safe service of metallic materials at high temperatures. However, premature failure is usually caused by spallation of scales from the matrix. Although few mechanisms have been proposed to understand this phenomenon, consensus has not yet been reached. In this study, we reveal that trace sulfur impurities contaminated in high-purity raw materials prominently segregate to the interface and form a thin intermediate amorphous-like layer between the oxide scale and alloy matrix during the oxidation process. Subsequently, cracking and spallation occur preferentially between the sulfur-rich layer and alumina scale due to the weak bonding between sulfur and alumina atoms. We validate the revealed atomistic spalling mechanism by successfully eliminating the detrimental effect of sulfur via microalloying. Our findings are useful for improving adhesion of oxide scales and enhancing heat-resistant properties of other high-temperature alloys.

Suggested Citation

  • Congcong Li & Wenjin Zheng & Haonan Zhong & Xiongjun Liu & Huihui Zhu & Hui Wang & Yuan Wu & Xiaobin Zhang & Zhiyang Yu & Suihe Jiang & Zhaoping Lu, 2025. "Unveiling the atomistic mechanism of oxide scale spalling in heat-resistant alloys," Nature Communications, Nature, vol. 16(1), pages 1-7, December.
    • Handle: RePEc:nat:natcom:v:16:y:2025:i:1:d:10.1038_s41467-025-57635-7
    DOI: 10.1038/s41467-025-57635-7
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