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The oxidation behavior of electroless Ni-P coated AISI 430 alloy was investigated at 800 °C in moisture-saturated (~ 3% H 2 O) air. Effect of pre-reduction in dry hydrogen (Ar-3%H 2 ) at 800 °C on the oxidation behavior of the Ni-P coated AISI 430 was also studied. Microstructure, chemical composition, and compound/oxide phase formation across the oxide layer were analyzed by scanning electron microscopy, energy dispersive spectroscopy, and X-ray diffraction techniques. Iron oxide Fe 2 NiO 4 spinel along with other oxide and spinel phases are found in the multilayered oxide scale for both the Ni-P coated and pre-reduced Ni-P coated AISI 430 alloy. Ni-P coating crystallization and oxidation initiates the oxidation for the electroless sample. Ni 3 P and FeNi 3 intermetallic compounds formed during reduction initiates the oxidation of the pre-reduced sample.

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Solid oxide fuel cells (SOFCs) have the potential to meet the growing need for electrical power generation if the cost per megawatt can be further reduced. Currently, SOFC stacks are replaced too frequently to be cost competitive. SOFC service life can be extended by preventing chromium- (Cr-) bearing species from evaporating from the interior surfaces of balance of plant (BOP) components and poisoning the cathode to increase the lifetime. We have developed yttria-stabilized zirconia (YSZ) and aluminum oxide- (Al2O3-) modified sol-gel paints or inks for coating BOP components. 430 stainless steel (430SS) substrates with three surface conditions were coated with the 0.8–1.5 µm thick YSZ and Al2O3 paints. The coated 430SS samples were tested for thermal cycling resistance, thermal soak, and Cr evaporation. Thermal soak and thermal cycling test results show promise for the YSZ-coated 430SS substrates. The Cr evaporation test of a coated substrate showed a 51% reduction in Cr generation, when compared with a bare substrate.