Residual stresses in convoluted oxide scales

Alumina scales that grow during oxidation of FeCrAl alloys can develop a convoluted morphology. Although convolution relieves the overall growth stress, high thermal stresses develop locally and can be detrimental to the scale or interface integrity. Ruby fluorescence measurements and finite element simulations are used to examine residual thermal stresses and strains that result when the convoluted scales are cooled to room temperature. Unlike a flat scale that is in biaxial compression, a convoluted scale contains significant gradients, with tensile stress components along the outside and near the interface of the convoluted peaks. The experimental results are in good agreement with model calculations and provide much needed verification of the model assumptions. Because the ruby fluorescence technique provides only the hydrostatic stress averaged over an excited volume that includes the entire alumina scale thickness, modeling provides detail and insight to the experimental measurements.