Progress of High Temperature Corrosion Behavior of Structural Materials in Molten Chloride Environment

doi:10.11901/1005.3093.2025.259

Chinese Journal of Materials Research

2026, Vol. 40

Issue (10): 721-732 DOI: 10.11901/1005.3093.2025.259

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Progress of High Temperature Corrosion Behavior of Structural Materials in Molten Chloride Environment

LIN Xinshun¹, CHEN Sihan²(

), SU Yunhai¹, XUE Hailong¹, JIANG Haichang²(

), RONG Lijian², LIN Rushan³

^1.School of Materials Science and Engineering, Shenyang University of Technology, Shenyang 110870, China
^2.CAS Key Laboratory of Nuclear Materials and Safety Assessment, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
^3.China Institute of Atomic Energy, Beijing 102413, China

Cite this article:

LIN Xinshun, CHEN Sihan, SU Yunhai, XUE Hailong, JIANG Haichang, RONG Lijian, LIN Rushan. Progress of High Temperature Corrosion Behavior of Structural Materials in Molten Chloride Environment. Chinese Journal of Materials Research, 2026, 40(10): 721-732.

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Abstract

Chloride molten salts, endowed with excellent physicochemical properties, exhibit broad application prospects in the electrochemical separation of spent nuclear fuel (SNF) and molten salt reactors (MSRs), in which they function as electrolytes, fuel solvents and coolants. However, the high-temperature, strongly chlorinating, and oxidizing environment of molten salt systems poses severe challenges to the corrosion resistance of structural materials, which has become the key factor restricting their engineering applications. In this study, the corrosion behaviors of stainless steels and Ni-based superalloys in molten salt environments are systematically reviewed, with a focus on the effects of various factors, including alloying elements, corrosive environments, temperatures and impurities (water and oxygen). Studies have indicated that Ni-based superalloys exhibit superior corrosion resistance compared with stainless steels due to the incorporation of a large number of refractory metal elements. Molten salt purification can effectively reduce the impurity content in the system, thereby significantly mitigating material corrosion. In chloride molten salt environments, uranium (U) exerts a significant influence on the corrosion resistance of alloys. However, its radioactivity and other inherent properties impose stringent requirements on the experimental conditions for related studies. Given the similarities in physicochemical properties such as ionic radius between U and cerium (Ce), this study investigates the mechanism by which CeCl₃ affects the corrosion resistance of materials in molten salt systems. These findings provide important insights into the corrosion behavior of materials induced by U in molten salts. Currently, the corrosion of metallic materials in high-temperature molten salts remains a major bottleneck in the development of SNF reprocessing technology. Future research should focus on developing commercial alloys with excellent corrosion resistance to chloride molten salts, and further exploring their corrosion mechanisms and influencing factors, thereby providing critical support for the advancement of SNF reprocessing technology.

Key words: metallic materials molten salt corrosion chloride molten salt nickel-based alloy spent nuclear fuel

Received: 20 August 2025

ZTFLH:

TG172.6

Fund: Lingchuang Research Proiect of China National Nuclear Corporation(CNNC-LCKY-2024-092)

Corresponding Authors: CHEN Sihan, Tel: (024)23971985, E-mail: shchen17b@imr.ac.cn;
JIANG Haichang, Tel: (024)23975312, E-mail: hcjiang@imr.ac.cn

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	LIN Xinshun
	CHEN Sihan
	SU Yunhai
	XUE Hailong
	JIANG Haichang
	RONG Lijian
	LIN Rushan

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https://www.cjmr.org/EN/10.11901/1005.3093.2025.259 OR https://www.cjmr.org/EN/Y2026/V40/I10/721

Fig.1 Corrosion mechanism of P91 in molten NaCl-KCl under an inert atmosphere (Ar)^[18]

Fig.2 Cr depletion depths of alloys exposed to molten NaCl-KCl-MgCl₂ at 700 ^oC for 100 h ^[23]

Fig.3 Scatter plot of corrosion rate of nickel-based alloys tested in chloride molten salt (a), and content diagram of Cr and Mo in nickel-based alloys (b)^[30~34,56]

Fig.4 Activities of Ni, W, and Cr in ternary Ni-xW-6Cr alloy^[45]

Fig.5 Schematic diagrams of simulation setups for three corrosion types (a) molten salt corrosion^[69], (b) high-temperature steam corrosion^[47], (c) molten salt/gas interface corrosion^[36]

Fig.6 Surface morphology and composition analysis of GH3535 alloy after molten salt corrosion for 300 h (a, c) solid-solution state, (b, d) GBE-treated state^[50]

Fig.7 Schematic diagram of purification using dual magnesium electrodes and AC voltage. Left (Phase 1): Removal of impurities and production of MgO on the cathode; Right (Phase 2): MgO falling off the electrode due to Mg→Mg²⁺ dissolution^[24]

Fig.8 (a, b) Proposed corrosion mechanisms of P91 in molten NaCl-KCl in inert atmosphere (Ar), highlighting the influence of the partial pressure of O₂ on the reactions involved, and (c, d) thermodynamic stability diagrams of the Fe-Cl-O and Cr-Cl-O systems at 700 ^oC, with lines marked as a, b and c denoting the equilibrium pressures of FeCl₂, CrCl₂ and CrCl with their respective oxides ^[18]

Fig.9 Schematic representation of the critical crevice chemistry that develops within an active crevice^[57]

Fig.10 Diffusion coefficient plots of UCl₃ and CeCl₃ at different temperatures ^[59]

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