Abstract
Effects of minor alloying elements (Si, Mn, and Al) on the corrosion resistance behaviors of stainless steel (SS) modified 310S used as a cathode current collector (CCC) material for molten carbonate fuel cells (MCFC) were examined in a mixture of 62 mol% Li2CO3–38 mol% K2CO3 at 650 °C by measuring the change in corrosion potential and the potentio-dynamic, potentio-static polarization responses. The corrosion potential of modified 310S gradually increased after 9 h of immersion due to an active to passive transition and that of SSs added with minor alloying elements drastically increased before 6 h of immersion due to the reactive alloys. Si, Mn, and Al addition to base SS led to a decrease in corrosion resistance due to the rapid corrosion rate at the cathode operation potential, −40 mV, of the MCFC. The steady state current densities of SSs added with minor alloying elements were higher than that of 310S and modified 310S. Addition of Si, Mn, and Al induced a decrease in corrosion resistance of CCC materials in molten carbonate fuel cell operating temperatures, 650 °C.
1 Introduction
The molten carbonate fuel cell (MCFC) is a power generation system that converts chemical energy of fuel (hydrogen, H2) directly to electrical energy by electrochemical reactions at high operating temperatures above 600 °C. It has been recognized as an attractive power generation system due to its great advantages such as high electrical efficiency (Bischoff 2006; Mitsushima et al. 2002), fuel flexibility (Blomen and Mugerwa 1993), and high grade waste heat recovery (Lunghi et al. 2003). These great advantages enable the use of large capacity electric storage systems in which can replace the present thermal and coal-fueled power plants (Dicks 1996).
The components of the MCFC consist of the anode, cathode, a carbonate electrolyte and ceramic powder (usually lithium aluminate, LiAlO2) impregnated matrix and ipolar plate. The bipolar plate is also called the current collector due to its role of providing electronic connection. It also serves as the single cell housing and separates the fuel from the oxidizer. During MCFC operation, the cathode current collector usually exposed to a eutectic 62 mol% Li2CO3–38 mol% K2CO3 gas and a N2–15 vol% O2–30 vol% CO2 gas mixture. The operating temperature of the cell is 650 °C which is above the eutectic temperature of electrolyte. Owing to these severe conditions, most cathode current collector (CCC) materials experience corrosion. This problem causes significant reduction in electrical conductivity and losses in electrolyte resulting in degradation in cell performance and long-term stability of MCFC (Biedenkopf et al. 1997; Donado et al. 1984; Hsu et al. 1987a,b; Perez et al. 2000).
Corrosion mechanism and performance degradation: The corrosion mechanism of the CCC using stainless steel is described as oxide formation by the reaction between the material and the molten carbonate. Lithium ions are transferred to the CCC surface through the lithiated cathode and react with metal ions of stainless steel to form lithiated oxide, e.g., LiFeO2 and LiCrO2 (Vossen et al. 1994, 1995). Since lithium ions and metal ions are continuously supplied, lithiated oxides continue to grow in the MCFC operating environment. The outermost layer is an insoluble lithium–ferrous oxide (LiFeO2) formed by a reaction between iron oxide and Li2CO3. LiFeO2 is followed by a compact Cr rich oxide layer and lastly in the Cr depleted region a soluble chromate layer is formed under the oxidizing gas conditions of the cathode side (Kumar Sharma et al. 2019). The formation and growth of oxides significantly reduce the electrical conductivity of the CCC (Soohoon et al. 2014). In addition, the chromate layer adds to the losses of electrolyte by reacting with potassium ion in electrolyte and also inducing a voltage loss (Durante et al. 2005; Kumar Sharma et al. 2019; Yuh et al. 1995).
Efforts of corrosion mitigation: Many studies have been conducted to overcome the problems caused by corrosion. In particular, through the analysis of the effect of alloying elements on corrosion rate and oxide stability, austenitic stainless steel is widely selected as a CCC material regarding the role of alloying elements in the corrosion resistance of commercial steels, chromium is the element which confers the best corrosion resistance under cathode condition, whereas nickel is less important of has slight negative effect in oxidizing environments (Frangini 2003).
The selection of CCC materials based on a full understanding of the effects of alloying elements on corrosion resistance of CCC materials in MCFC environments is therefore very important to increase the life time of MCFC (Frangini 2003; Vossen et al. 1996a,b).
In our previous study, we focused on the initial stages of oxidation of commercial CCC materials, SS 310S and SS 316L, in order to find out the optimum CCC material for a durable MCFC with high performance. We analyzed the structures and compositions of the oxide layers that were formed on the surfaces of CCC materials. We also examined the electrochemical corrosion behavior of the CCC materials in a eutectic 62 mol% Li2CO3–38 mol% K2CO3 mixture at 650 °C in CO2–O2 gas mixture environments. Through our study, we found out that the Cr content in SS is the most important factor in obtaining corrosion resistance in CCC materials in MCFC operating environments (Soohoon et al. 2014). Ever after, previous researcher had been developed CCC materials through modify alloying elements such as Si, Mn, and Al in SS. However, researcher focused on the improvement in the surface properties of the materials as a result of protective coatings using spray and slurry (Aguero et al. 2001; Biedenkopf 2005; Frangini and Masci 2004; Guo et al. 2012; Jaeho et al. 2002; Keijzer et al. 1977; Parezanovic et al. 2004; Perez et al. 2002; Schoeler et al. 2000; Wang et al. 2006).
In this study, we focused on the corrosion behavior of CCC materials – SS 310S, SS modified 310S and SS added with minor alloying elements – at actual cathode operating potentials of MCFC. The potentio-static polarization technique is utilized which enables the acquisition of a quantitative steady state current density of each SS. The electrochemical corrosion behavior of CCC materials in molten carbonate fuel cell environments and the effect of minor alloying elements such as Si, Mn, and Al on the life time of high performance MCFC is studied.
2 Materials and methods
Electrochemical experiments were performed in a high temperature corrosion reactor. The reactor mimics an MCFC operation environment. The reactor structure and the electrode geometry are shown in Figure 1. Target chemical compositions of the cathode current collector materials used in this work are shown in Table 1. All materials were supplied from POSCO, KOREA. The Cr and Ni contents of the SS modified 310S and the amounts of SSs added with minor alloying elements were left blank due to the intellectual properties of POSCO. SS 310S had higher Cr and Ni content compared with those in SS modified 310S and SSs added with minor alloying elements.

Cross-section of high temperature corrosion reactor with the layout of the working, reference and counter electrodes. Adapted (reproduced from) from Soohoon et al. (2014) with permission of Elsevier.
Target chemical compositions of the alloys used in this study (wt%).
C | Mn | Si | Al | Cr | Ni | W | Ti | Nb | |
---|---|---|---|---|---|---|---|---|---|
SS 310S | 0.04 | 1.40 | 0.40 | 0.05 | 25.00 | 19.50 | – | – | – |
SS modified 310S (base SS) | 0.06 | 0.50 | 0.50 | – | Blank | Blank | 0.05 | 0.018 | 0.20 |
1.0 Si | 0.06 | 0.50 | 1.00 | – | Blank | Blank | 0.05 | 0.018 | 0.20 |
2.0 Si | 0.06 | 0.50 | 2.00 | – | Blank | Blank | 0.05 | 0.018 | 0.20 |
1.5 Mn | 0.06 | 1.50 | 1.00 | – | Blank | Blank | 0.05 | 0.018 | 0.20 |
3.0 Mn | 0.06 | 3.00 | 2.00 | – | Blank | Blank | 0.05 | 0.018 | 0.20 |
0.1 Al | 0.06 | 0.50 | 0.50 | 0.10 | Blank | Blank | 0.05 | 0.018 | 0.20 |
The schematic of the electrode used in the electrochemical experiments shows in Figure 2. The wire type working electrode having a width of 0.5 mm was covered with an alumina tube. One end of the SS was exposed to the electrolyte and the other end of wire was connected to the potentiostat. The working electrode was grounded with a 600-grit silicon carbide paper on all sides and then ultrasonically cleaned with ethanol. A counter electrode made of 99.999 % pure gold wire was used. A pure gold wire covered with alumina tube served as a reference electrode, which was immersed in a carbonate electrolyte containing a LiAlO2 salt bridge. This alumina tube had a hole less than 0.3 mm in diameter at the bottom. The carbonate electrolyte of reference electrode and the carbonate electrolyte in the reactor move each side through the small hole. The reference electrode gas was mixture of 67 vol% carbon dioxide + 33 vol% oxygen. All potentials mentioned in this study were measured verses the following reaction at the reference electrode (CO32− = CO2 + 1/2O2 + 2e−). The inlet gases to the reactor were air and carbon dioxide. The flow rates of each gas were 50 cc/min for carbon dioxide and 100 cc/min for air. The composition of the carbonate electrolyte was the standard 62:38 Li2CO3:K2CO3 mixture. The reactor temperature was kept at 650 °C and the outlet gas was vent through the fume hood.

Schematic diagram of the 3 electrodes. Adapted (reproduced from) from Soohoon et al. (2014) with permission of Elsevier.
For corrosion potential measurement, the specimens were immersed in the carbonate electrolyte for 12 h with 15 s interval sampling rates. The corrosion behavior of each alloy was determined from potentio-dynamic (PD) and potentio-static (PS) polarization response studies. PD polarization tests were carried out for 600 s during immersion. The potential of each alloy was swept at a rate of 1 mV/s from an initial potential of −50 mV with respect to the corrosion potential. PS polarization tests were carried out during the first 10 min of immersion where then the applied potential was stepped to a calculated CCC operation potential of −40 mV for 4000 s. Once the step potential was applied, the corrosion current abruptly increased to a peak and decayed to a steady state. The peak current represents the tendency of alloys to corrode and the steady-state current density represents the corrosion rates of alloys.
3 Results and discussion
3.1 Corrosion potential measurements
The corrosion potential transient curves of SS modified 310S (=base SS) and SSs added with minor alloying elements in a (Li62K38)2CO3 electrolyte at 650 °C are shown in Figure 3. The corrosion potential of each SS increased with immersion time due to the formation of oxide layers. The corrosion potential transient curve of base SS is divided into three stages depending on the slope of the curve. The first stage is during the first 4 h of immersion where the slope is positive and the potential is swept from −1.0 V to −0.6 V. The second stage is during the next 4 h where the magnitude of the slope is smaller than that of the 1st stage and the potential is swept from −0.6 V to −0.5 V. The third stage during the last 4 h when the magnitude of the slope becomes same as the first stage but when the measurement ends. The final corrosion potential was −0.2 V. The corrosion potential of SSs added with minor alloying elements increased rapidly. The potential curve looked as a contracted curve of the corrosion potential transient curve of base SS with respect to the time axis. This meant that the corrosion rate of SSs added with minor alloying elements was faster than that of base SS.

Corrosion potential of base SS and SS with minor alloying elements during immersion in 62 mol% Li2CO3–38 mol% K2CO3 mixture at 650 °C.
3.2 Potentio-dynamic polarization responses
The PD polarization responses of SS 310S, base SS, and Si added SSs during 600 s of immersion in (Li62K38)2CO3 electrolyte at 650 °C are shown in Figure 4a. All the SSs showed active behavior at corrosion potentials. With increasing electrode potential, each SS was subjected to active and passive behavior. The quantitative values of corrosion potential, corrosion current density, critical current density, and passive current density at −40 mV of all SSs are summarized in Table 2. The corrosion potentials of each SS were similar and were between −1.02 V and −0.89 V. The corrosion rates of each SSs were similar and were between 0.0644 mA/cm2 and 0.1197 mA/cm2. The critical current density decreased in the case of Si added SSs. The corrosion resistance of SS 310S and base SS in active regions was similar or slightly lower than Si added SSs. There were different corrosion aspects of alloys, however, in the passive regions between −0.8 V and 0 V. In case of Si added SSs, the passive current density of each SS decreased in the lower electrode potential passive regions, −0.8 V to −0.4 V. The addition of Si to base SS increased the passive current density in the higher potential passive regions, −0.4 V to 0 V, where there was little difference in the passive current densities in base-1Si SS and base-2Si SS. This meant that Si addition to base SS led to a decrease in corrosion resistance of SS due to a rapid corrosion rate in higher electrode potential regions. This is important since the operation potential of the MCFC cathode is in the higher electrode potential regions.

PD polarization responses of SS 310S, base SS, and SSs added with minor alloying elements in 62 mol% Li2CO3–38 mol% K2CO3 mixture at 650 °C.
Corrosion potential and corrosion current densities of SSs in (Li62K38)2CO3 electrolyte at 650 °C.
Specimen | Corrosion potential (V vs. Au[O2:CO2 = 1:2]) | Corrosion current density (mA/cm2) | Critical current density (mA/cm2) | Passive current density at −40 mV (mA/cm2) |
---|---|---|---|---|
SS 310S | −0.899 | 0.1197 | 3.984 | 0.765 |
SS modified 310S (base SS) | −1.020 | 0.0644 | 10.54 | 1.034 |
1.0 Si | −0.928 | 0.1083 | 1.583 | 3.833 |
2.0 Si | −0.897 | 0.0788 | 0.940 | 2.351 |
1.5 Mn | −0.875 | 0.2061 | 1.674 | 2.824 |
3.0 Mn | −0.881 | 0.1044 | 1.817 | 2.780 |
0.1 Al | −0.933 | 0.0718 | 2.165 | 6.041 |
The PD polarization responses of SS 310S, base SS and Mn added SSs during 600 s of immersion in a (Li62K38)2CO3 electrolyte at 650 °C is shown in Figure 4b. At corrosion potential, all the SSs showed active behavior and the corrosion potentials of each SS were located between −1.02 V and −0.87 V. The corrosion rates of each SS were similar and they were measured between 0.0644 mA/cm2 and 0.2061 mA/cm2. The critical current density decreased with Mn content. Corrosion resistance of SS 310S and base SS in active regions, therefore, were similar or slightly lower than Mn added SSs. On the other hand, the corrosion resistance of SSs decreased with increasing Mn content in higher electrode potential passive regions due to higher passive current densities. There was little difference in the passive current density between base-1.5Mn SS and base-3.0Mn SS. This meant that Mn addition to base SS lead to a decrease in corrosion resistance due to the rapid corrosion rate at the operational potential of MCFC cathode.
The PD polarization responses of SS 310S, base SS and Al added SS during 600 s of immersion in a (Li62K38)2CO3 electrolyte at 650 °C are shown in Figure 4c. With increasing electrode potential, each SS was subjected to active and passive behaviors. The corrosion potentials of each SS were similar and were located between the −1.02 V and −0.93 V ranges. The corrosion rates of each SS were similar and they were measured between 0.0644 mA/cm2 and 0.0718 mA/cm2. The critical current density of Al added SS was lower than that of base SS. Corrosion resistance of Al added SS was slightly higher than that of base SS in the active region. Degradation in corrosion resistance of Al added SS was observed at the operation potential of MCFC cathode due to its higher passive current density.
3.3 Potentio-static polarization responses
We examined the corrosion behavior of base SS and SSs added with minor alloying elements at MCFC cathode operating potential using PS polarization measurement. The transient curve of input potential and output current for description of the test is shown in Figure 5. P1 denotes the corrosion potential (0 V vs. ref. electrode) of the working electrode and P2 denotes the operating potential at the MCFC cathode. Equations (1) and (2) show the electrochemical reaction at the MCFC cathode and the Nernst equation, respectively.

Transient behavior of input potential and measured currents during PS polarization test. P1, corrosion potential; P2, calculated operation potential at MCFC cathode; timm, 600 s (immersion time); C1, corrosion current density; C2, peak current density; and C3, steady-state current density.
The electrochemical reaction potential (=E) is 0 V at dynamic equilibrium. We calculated the standard reduction potential (=
R is the gas constant (
Considering the purging gas flow rate (air 100 cc/min + CO2 50 cc/min) to the electrolyte, finally, the electrochemical reaction potential (=E, operating potential at the MCFC cathode) is calculated, −0.04 V.
t imm is the initial delay time, 600 s, which is the same value as in the PD test. C1 is the corrosion current density of the working electrode, C2 is the peak current density of the alloys representing the tendency of oxidation, C3 is the steady state current density at an applied voltage and P2 represents the corrosion resistance of the alloys.
The current transient curves of SS 310S, base SS and Si added SSs in (Li62K38)2CO3 electrolyte at 650 °C obtained by PS polarization measurement is shown in Figure 6a. At corrosion potential, all the SSs yielded corrosion current density. As the potential was step up to −40 mV, the current abruptly increased to a maximum point and smoothly decreased to a steady state. The peak and steady state current densities of the SSs are shown in Table 3. No change in magnitude of peak current density was observed with changes in amounts of Si which showed that Si addition had no influence on oxidation. The current decay time of Si added SSs was longer than that of base SS and there was little difference in that between base-1Si SS and base-2Si SS. Si addition to base SS lead to a decrease in corrosion resistance due to a higher steady state current density of SSs.

Transient behavior of SS 310S, base SS, and SSs added with minor alloying elements in 62 mol% Li2CO3–38 mol% K2CO3 mixture at 650 °C.
Peak current densities and steady state current densities of SSs in (Li62K38)2CO3 electrolyte at 650 °C.
Specimen | Peak current density (mA/cm2) | Steady state current density (mA/cm2) |
---|---|---|
SS 310S | 1.80 | 0.36 |
SS modified 310S (base SS) | 4.51 | 0.64 |
1.0 Si | 7.27 | 2.04 |
2.0 Si | 4.52 | 1.94 |
1.5 Mn | 3.27 | 1.62 |
3.0 Mn | 5.06 | 2.20 |
0.1 Al | 3.63 | 1.27 |
The current transient curves of SS 310S, base SS and Mn added SSs in (Li62K38)2CO3 electrolyte at 650 °C obtained by PS polarization measurements are shown in Figure 6b. With a step up in potential from the corrosion potential to −40 mV, the current showed a peak and then maintained a steady state constant value. There was no significant effect of Mn on the tendency of oxidation due to the absence of peak current density with increasing Mn content. The current decay time of Mn added SSs was longer than that of base SS and there was little difference in that between base-1.5Mn SS and base-3Mn SS. Mn addition to base SS lead to a decrease in corrosion resistance of SS due to a higher steady state current density of SS.
The current transient curves of SS 310S, base SS, and 0.1 Al added SS in (Li62K38)2CO3 electrolyte at 650 °C obtained by PS polarization measurements is shown in Figure 6c. The peak current density of Al added SS was lower than that of base SS. This meant that Al addition lead to a decrease in the tendency of oxidation in the MCFC cathode environment. The current decay time of Al added SSs was similar with that of base SS. Al addition to base SS, however, lead to a decrease in corrosion resistance of SS due to a higher steady state current density of SS.
The electrochemical corrosion behavior of SS 310S, SS modified 310S, and SS added with minor alloying elements in MCFC operating environments was analyzed through quantitative data such as passive current density and steady state current density. These quantitative data show that Si, Mn, and Al addition to base SS lead to a decrease in corrosion resistance of SS. Therefore, as of now, SS 310S is necessary to be continued using as a CCC material in MCFC. We found out that the Cr content in SS is the major factor in obtaining corrosion resistance in CCC materials in MCFC operating environments in our previous study (Soohoon et al. 2014). Considering the cost aspect, a material is being developed in which the content of Cr is reduced and the minor alloying elements are controlled. For this reason, the quantitative data of electrochemical examination should be utilized in the process of developing new material with corrosion resistance equal to or higher than SS 310S.
4 Conclusions
The corrosion potential of SSs added with minor alloying elements was increased than that of base SS. The corrosion potential transient curves seemed contracted with respect to the time axis compared to those of base SS. This meant that the corrosion rates of SSs added with minor alloying elements was faster than those of base SS. Si, Mn, and Al addition to base SS lead to a decrease in corrosion resistance of SS due to rapid corrosion rates at the MCFC cathode operated potential, −40 mV, when measured by PD polarization tests. The lower corrosion resistance of SSs added with minor alloying element addition compared with SS 310S and base SS is due to the longer current decay time and lower steady state current density measured by PS polarization tests. Addition of Si, Mn, and Al produced a decrease in corrosion resistance of CCC materials in molten carbonate fuel cell operating temperatures, 650 °C.
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Research ethics: Not applicable.
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Author contributions: The authors have accepted responsibility for the entire content of this manuscript and approved its submission.
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Competing interests: The authors state no conflict of interest.
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Research funding: None declared.
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Data availability: The raw data can be obtained on request from the corresponding author.
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Articles in the same Issue
- Frontmatter
- Reviews
- Corrosion inhibition performance of organic compounds and theoretical calculations based on density functional theory (DFT)
- Electro-chemo-mechanical properties of anodic oxide (passive) films formed on Cu, Ni and Fe
- Tribocorrosion in biomaterials and control techniques: a review
- Concrete corrosion in nuclear power plants and other nuclear installations and its mitigation techniques: a review
- Original Articles
- Study on corrosion behavior of typical carbon steel and low alloy steel in deep sea of different sea areas
- Effects of minor alloying elements (Si, Mn and Al) on the corrosion behavior of stainless steels in molten carbonate fuel cell cathode environment
- Microstructural characteristics of different heat-affected zones in welded joints of UNS S32304 duplex stainless steel using the GMAW process: analysis of the pitting corrosion resistance
- Inhibition efficiency and mechanism of nitrilo-tris(methylenephosphonato)zinc on mild steel corrosion in neutral fluoride-containing aqueous media
- Annual Reviewer Acknowledgement
- Reviewer acknowledgement Corrosion Reviews volume 41 (2023)