- Research Article
- 10.1149/ma2025-031452mtgabs
The Dual Atmosphere Effect - 20+ Years of Research
- Nov 24, 2025
- Electrochemical Society Meeting Abstracts
- Kerem Ozgür Gunduz + 3 more +3
The interconnects in a SOFC or SOEC stack are subject to a high temperature environment with air or O2 on one side and a H2/H2O mixture on the other. This so-called dual atmosphere is known to result in corrosion that differs from the results obtained in experiments where the steel is exposed to only one of these atmospheres. In SOFC context a dual atmosphere effect was first reported by Yang et al. in 2003 [1]. They reported that AISI 430 exposed to dual atmosphere conditions (air // H2-3%H2O) formed a more Fe rich oxide scale, including the presence of Fe2O3, on the air side while a reference experiment with air on both sides resulted in a protective oxide scale of Cr2O3 and spinel. This triggered a stream of investigations studying various FSS under dual atmosphere conditions. Most of these studies focused on temperatures of 800-900°C (relevant operating temperatures for SOFCs at that time) and gave contradictory results. Some authors confirmed Yangs findings [2] or found an even more severe effect [3]while others reported only a slight enrichment of Fe in the oxide scale or no observable effect at all [4–7]. Nevertheless, there is agreement that the dual atmosphere effect is only observed on the air side and the fuel side is unaffected of whether the other side of the sample is exposed to air or H2/H2O. Subsequent work by Alnegren et al. [8] and Gunduz et al [9] investigated AISI 441 under dual atmosphere conditions at temperatures between 500-800°C. These studies showed the most severe dual atmosphere effect was observed at 600°C and that higher temperatures, somewhat counterintuitive, resulted in more protective oxide scales. The apparent contradictions in the results have led some authors to attribute the dual atmosphere effect to leakages or sealant contamination and questioned its practical relevance [10]. This work revisits these earlier studies to discuss factors that might explain the discrepancies observed and allows for a reinterpretation of the previous findings.Figure 1 shows the piping made of 316L stainless steel leading towards the dual atmosphere sample holder after the first experiment at 600°C (temperature of the pictured section was <600°C). While the steel pipe with air on the inside shows a thin protective scale its counterpart that was filled with Ar-5%H2 is massively corroded on the air side. Similar results with tubular specimens of AISI 316L were published by Holcomb et al [11]. Hence, there is an abundance of studies confirming the existence of a dual atmosphere effect. It is also commonly agreed upon that hydrogen diffuses through the metal affecting air side oxidation. Nevertheless, the underlying mechanism of how hydrogen affects the air side oxidation is elusive. In this contribution the merits of different proposed mechanisms will be discussed. Finally, mitigation strategies to prevent dual atmosphere corrosion will be reviewed.
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