In this work, on-site corrosion behavior of heat resistant tubes of T91, used as components of a superheater in a power plant for up to 25,762 h, has been investigated using scanning electron microscopy(SEM), energy dispersive X-ray spectroscopy (EDS), and electron backscattered diffraction(EBSD), with the objectives of studying the composition, phase distribution, and evolution during service. A multi-layer structure of oxide scale was found on both the steamside and the fireside of the tube surface; the phase distribution was in the order of hematite/magnetite/spinel from the outer to the inner matrix on the steamside, and in the order of slag/magnetite/spinel from the outer to the inner matrix on the fireside. The magnetite layer was found to be rich in pores and cracks. The absence of a hematite layer on the fireside was considered to be due to the low oxygen partial pressure in the corrosion environment. The thicknesses of the hematite and of the slag-deposit layer were found to exhibit no significant change with the increase of the service time.

The microstructural evolution of Grade 91 tempered martensite ferritic steels heat treated at 760~1000 oC for two hours was investigated using scanning electron microscopy(SEM), energy disperse spectroscopy(EDS), electron backscattered diffraction (EBSD), and transmission electron microscopy(TEM); a microhardness tester was also employed, with a focus on the grain and precipitate evolution process as well as on the main hardening element. It was found that an evolution of tempered martensite to ferrite(760~850 oC), and to fresh martensite(900~1000 oC), occurred with the increase of temperature. Simultaneously, the parabolic evolution characteristics of the low angle grain boundary(LAGB) increased with the increase of the heating temperature(highest fraction of LAGB at 925 oC), indicating grain recovery upon intercritical heating. The main precipitate, M23C6, was found to be coarsened slightly at 760~850 oC; it then dissolved at 850~1000 oC. Besides this, M3C cementite was formed at 900~1000 oC. Finally, the experimental results show that the hardness of the steel depended largely on the matrix structure, rather than on the precipitates, with the fresh martensite showing the highest hardness value.

The effects of coating thickness on the delamination and fracture behavior of thermal barrier coating (TBC) systems were investigated with cyclic flame thermal fatigue (FTF) and thermal shock (TS) tests. The top and bond coats of the TBCs were prepared by electron beam-physical vapor deposition and low pressure plasma spray methods, respectively, with a thickness ratio of 2:1 in the top and bond coats. The thicknesses of the top coat were 200 and 500 μm, and those of the bond coat were 100 and 250 μm. FTF tests were performed until 1140 cycles at a surface temperature of 1100 oC for a dwell time of 5 min. TS tests were also done until more than 50 % delamination or 1140 cycles with a dwell time of 60 min. After the FTF for 1140 cycles, the interface microstructures of each TBC exhibited a sound condition without cracking or delamination. In the TS, the TBCs of 200 and 500 μm were fully delaminated (> 50 %) within 171 and 440 cycles, respectively. These results enabled us to control the thickness of TBC systems and to propose an efficient coating in protecting the substrate in cyclic thermal exposure environments.