Effects of Nickel on the Oxide/Metal Interface Morphology and Oxidation Rate During High-Temperature Oxidation of Fe–Cu–Ni Alloys

Steel produced in an electric arc furnace (EAF) contains a high amount of Cu that causes a surface-cracking phenomenon called surface hot shortness. Ni reduces the risk for surface hot shortness, and this work focuses on investigating the following two phenomena caused by Ni during oxidation at 1150 °C for Fe–Cu–Ni alloys: (1) the decrease in oxidation rate and (2) the formation of a wavy liquid-Cu/oxide and of liquid-Cu/γ-iron (γFe) interfaces, which promote Cu occlusion into the scale. Thermogravimetry, scanning electron microscopy, and transmission electron microscopy-energy dispersive spectroscopy techniques were applied. A numerical model also was developed to explain the experimental results. High Ni contents cause higher liquid-Cu/γFe interface nickel concentrations and more potential for an interface breakdown. The decrease in oxidation rate by adding nickel can be explained qualitatively by the decrease in Fe cation transport through the wüstite layer.