Study on the Variation in Microstructure of a Ferritic Stainless Steel with Surface Roughness and Thermal Cycling in Air.

A ferritic stainless steel, Crofer 22 APU, is one of candidates for metallic interconnects of solid oxide fuel cells. Ferritic stainless steel Crofer 22 APU specimens with different surface roughnesses were prepared by grinding with SiC powder papers of various grits and were then thermally cycled. Polished Crofer 22 APU specimens after one thermal cycle and five thermal cycles had relatively straight oxide layers with similar thicknesses of 30 m, suggesting that after one cycle (total oxygen exposure time of 100 h at 1073 K), the oxidation does not progress. Micrographs of a trench made by milling with the FIB (focused ion beam) for a Crofer 22 APU specimen rubbed with grit 80 SiC powder paper after 8 thermal cycles (total oxygen exposure time of 200 h at 1073 K), captured by ESB, InLens, and SE2, showed that the surface of the sample was very coarse and its oxide layer was undulated. In the oxide layer, the phase of the sublayer was Cr₂O₃, and that of the top layer was (Cr, Mn)₃O₄ spinel. The sample ground with grit 80 SiC powder paper after 60 thermal cycles (total oxygen exposure time of 1500 h at 1073 K) was very coarse. Some ridges were quite straight and continuous. After 20 and 40 thermal cycles, ASR (area specific resistance) decreased as the number of grit of the SiC powder paper increased, suggesting that the polished Crofer 22 APU is better than those with rougher surfaces for application as an interconnect of SOFC.