Cyclic Oxidation Behavior and Protective Oxide Scale Formation in Stainless-Steel Alloys for High-Temperature Exhaust Valve Applications

As internal combustion engine (ICE) systems are increasingly exposed to severe thermal and oxidative environments, the oxidation resistance and structural integrity of exhaust valve materials have become critical for maintaining long-term engine reliability and efficiency. This study presents a comparative evaluation of the cyclic oxidation behavior of two candidate valve steels, 1.4718 (ferritic stainless steel) and 1.4871 (austenitic stainless steel), under service-temperature conditions. The specimens were exposed to repeated oxidation at 550 °C, 650 °C and 750 °C for 25 cycles in ambient air. The surface and cross-sectional morphologies of the oxide layers were analyzed using scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS) to investigate oxide scale composition, thickness, and growth characteristics. The oxidation behavior of both alloys proceeded in two distinct stages: an initial phase marked by accelerated oxidation, followed by a slower, more stable growth period. The extent of oxidation intensified with increasing temperature. The 1.4718 alloy developed relatively porous but compositionally stable oxide layers consisting primarily of Fe- and Cr-based spinels such as FeCr2O4 and Cr2SiO4. In contrast, the 1.4871 alloy formed a dense, adherent, dual-layered oxide scale composed of an outer Mn2O3-rich layer and an inner Cr2O3-rich layer, attributable to its high Mn and Cr content. The results underscore the critical influence of elemental composition, particularly Cr, Mn and Si, on oxide scale stability and spallation resistance, demonstrating the superior cyclic oxidation resistance of the 1.4871 alloy and its potential suitability for exhaust valve applications in thermally aggressive environments.