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Molten salts serve as effective high-temperature heat transfer fluids and thermal storage media used in a wide range of energy generation and storage facilities, including concentrated solar power plants, molten salt reactors and high-temperature batteries. However, at the salt-metal interfaces, a complex interplay of charge-transfer reactions involving various metal ions, generated either as fission products or through corrosion of structural materials, takes place. Simultaneously, there is a mass transport of ions or atoms within the molten salt and the parent alloys. The precise physical and chemical mechanisms leading to the diverse morphological changes in these materials remain unclear. To address this knowledge gap, this work employed a combination of synchrotron X-ray nanotomography and electron microscopy to study the morphological and chemical evolution of Ni-20Cr in molten KCl-MgCl2, while considering the influence of metal ions (Ni2+, Ce3+, and Eu3+) and variations in salt composition. Our research suggests that the interplay between interfacial diffusivity and reactivity determines the morphological evolution. The summary of the associated mass transport and reaction processes presented in this work is a step forward toward achieving a fundamental comprehension of the interactions between molten salts and alloys. Overall, the findings offer valuable insights for predicting the diverse chemical and structural alterations experienced by alloys in molten salt environments, thus aiding in the development of protective strategies for future applications involving molten salts.

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The corrosion behavior of alloy Ni 201 in molten sodium hydroxide (NaOH) at 600 °C was investigated at varying basicity levels of the molten NaOH. The ability for Ni 201 to form passivating oxides was investigated after immersion tests varying from 70 to 340 h under atmospheres of argon and argon with different partial pressure of water. Morphology and thicknesses of the corrosion products were characterized by Scanning Electron Microscopy (SEM) and crystallography of the corrosion products by X-ray Diffraction (XRD). Dynamic polarizations were made to investigate the effects of basicity and electrochemical potential. The results showed that Ni 201 corroded at a reduced rate in molten acidic NaOH compared to neutral NaOH due to the formation of NiO. The oxide scales formed on Ni 201 in acidic NaOH were shown to grow non-parabolically and did not result in full corrosion protection as the oxide scales showed crack development over time.

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This study designed a novel high-temperature corrosion-resistant alloy through thermodynamic equilibrium computations. The strength was determined by the integration of precipitation-strengthening species of nickel boride and tungsten solid solution strengthening, while high-temperature corrosion-resistant property was realized through optimized compositional design. Phase stability was enabled by the presence of a face-centered cubic structure. The alloy was fabricated and its corrosion-resistance performance was experimentally compared with other commercially available nickel- and iron-based alloys under simulated municipal solid waste combustion. The designed alloy with a composition of Ni-5B-6W-28Cr-13Al showed a low corrosion rate of ∼72 % < 13CrMo4-5TS and 1.08 % > Inconel 625. Economic analysis showed that Ni-5B-6W-28Cr-13Al has a cost-effectiveness ratio of 1:1.57 with respect to Inconel 625 and 1:0.09 with respect to 13CrMo4-5TS. Corrosion-resistance mechanism was explored using scanning electron microscopy coupled with energy dispersive spectroscopy, x-ray diffractometer, and DFT computations. The corrosion resistance occurred through the formation of a uniform tungsten-chromium-oxide film which inhibits inward diffusion of corrosive chlorine species. These findings provide insights into the development of alloys for high-temperature technologies.

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The corrosion behavior of alumina-forming austenitic (AFA) stainless steels with different Nb additions in a supercritical carbon dioxide environment at 500 °C, 600 °C, and 20 MPa was investigated. The steels with low Nb content were found to have a novel structure with a double oxide as an outer Cr2O3 oxide film and an inner Al2O3 oxide layer with discontinuous Fe-rich spinels on the outer surface and a transition layer consisting of Cr spinels and γ'-Ni3Al phases randomly distributed under the oxide layer. Oxidation resistance was improved by accelerating diffusion through refined grain boundaries after the addition of 0.6 wt.% Nb. However, the corrosion resistance decreased significantly at higher Nb content due to the formation of continuous thick outer Fe-rich nodules on the surface and an internal oxide zone, and Fe2(Mo, Nb) laves phases were also detected, which prevented the outward diffusion of Al ions and promoted the formation of cracks within the oxide layer, resulting in unfavorable effects on oxidation. After exposure at 500 °C, fewer spinels and thinner oxide scales were found. The specific mechanism was discussed.

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Understanding the mechanisms leading to the degradation of alloys in molten salts at elevated temperatures is significant for developing several key energy generation and storage technologies, including concentrated solar and next-generation nuclear power plants. Specifically, the fundamental mechanisms of different types of corrosion leading to various morphological evolution characteristics for changing reaction conditions between the molten salt and alloy remain unclear. In this work, the three-dimensional (3D) morphological evolution of Ni-20Cr in KCl-MgCl2 is studied at 600 °C by combining in situ synchrotron X-ray and electron microscopy techniques. By further comparing different morphology evolution characteristics in the temperature range of 500-800 °C, the relative rates between diffusion and reaction at the salt-metal interface lead to different morphological evolution pathways, including intergranular corrosion and percolation dealloying. In this work, the temperature-dependent mechanisms of the interactions between metals and molten salts are discussed, providing insights for predicting molten salt corrosion in real-world applications.

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The development trends in the energy sector clearly indicate an increase in the share of biomass and alternative fuels fed for combustion in power boilers, which results in the imposition of many unfavourable factors and a demanding working environment. During the operation of the energy system, this means a sharp increase in corrosion of the gas-tight pipe walls and coils by the destructive action of chlorine and sulphur. Implementing advanced surface protection in addition to the selection of materials of better quality and resistance to difficult working conditions would significantly reduce their wear by high temperature corrosion. Thermally sprayed coatings offer a great opportunity to protect machine components and energy systems against corrosion, erosion, impact load and abrasive wear. This article presents the test results of high-temperature corrosion resistance of coatings made with Ni-Cr-B-Si and Ni-B-Si alloy powders on a boiler steel substrate. Samples with sprayed coatings were exposed to an atmosphere with a composition of N2 + 9% O2 + 0.08% SO2 + 0.15% HCl at 800 °C for 250, 500, 750 and 1000 h. Tests results of coatings made of Ni-Cr-B-Si alloys subjected to the influence of a corrosive environment showed the formation of a layer of scale on the surface, composed mainly of Cr2O3 oxide, which was a passive layer, reducing the rate of corrosion. Coatings sprayed with Ni-B-Si alloys showed significantly lower corrosion resistance. It was found that the developed technology of subsonic flame spraying with powders of the Ni-Cr-B-Si type allows the production of coatings compliant with the requirements of the energy industry, which allows their use as anti-corrosion protection on boiler elements intended for waste disposal and biomass combustion.

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In this paper, the element nitrogen (N) is used to partially replace the element nickel (Ni) in flux-cored wire. A 44%Ni-24%Cr-0.18N nitrogen-containing low-nickel flux-cored wire with excellent corrosion resistance is prepared. The corrosion behavior of nitrogen-containing low-nickel weld cladding and Inconel 625 weld cladding in 40 KCl + 60 MgCl2 (wt%) molten salt at 900 °C is studied. The results show that the selective dissolution of Cr occurs in both weld claddings. The corrosion resistance of the 44%Ni-24%Cr-0.18N nitrogen-containing low-nickel weld cladding is better than that of the Inconel 625 weld cladding. The reason is that added N can react with H+ in molten salt to generate NH4+, remove corrosive impurities of MgOH+ in molten salt and change the corrosion environment. N preferentially combines with Cr to form Cr2N, reduces the diffusion precipitation of Cr and improves the corrosion resistance.

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Dilution rate is one of most important factors influencing the microstructure and performance of the laser cladding layer. In order to obtain a reasonable dilution rate in the laser cladding layer of Inconel 625 alloy, the laser cladding layers with different Fe content were prepared on the surface of 20# steel by the laser cladding technique. The influence of Fe content on the microstructure and performance of Inconel 625 alloy cladding layer was investigated. The results indicate that with the increase in Fe content in the alloy, the grain size of the cladding layer becomes coarser, the grain orientation difference increases first and then decreases, and the grain boundary angle decreases first and then increases. The hardness, high temperature wear resistance, and high temperature corrosion resistance gradually decreased. It is concluded that the dilution rate of Fe in laser cladding Inconel 625 alloy should be under 5 wt.%.

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Crevice corrosion behavior of Alloy 690 in high-temperature aerated chloride solution was studied using a self-designed crevice device. The SEM, EDS, XRD, and XPS analyses results indicated that the oxide films outside the crevice consisted of Ni-Cr oxides containing a small amount of hydroxides, and the oxide films on crevice mouth consisted of a (Ni,Fe)(Fe,Cr)2O4 spinel oxides outer layer and a Cr(OH)3 inner layer, and the oxide films inside the crevice consisted of a α-CrOOH outer layer and a Cr(OH)3 inner layer. When crevice corrosion occurred, the hydrolysis of Cr3+ led to the formation of Cr(OH)3 inside the crevice, and caused the pH value of crevice solution to decrease, and Cl- migrated from outside the crevice into inside the crevice due to electrical neutrality principle and accumulation. When the water chemistry inside the crevice reached the critical value of active dissolution of metal, the active dissolution of metal inside the crevice occurred. In addition, (Ni,Fe)(Fe,Cr)2O4 spinel oxides on the crevice mouth were formed by the deposition of metal ions migrated from inside the crevice. The mechanism of crevice corrosion and the formation mechanism of oxide films at different regions were also discussed.

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In this work, Ni-Cr-Mo cladding layers with different Si contents were prepared on Q235 steel using laser-cladding technology, and their corrosion characteristics were investigated in NaCl-KCl-Na2SO4-K2SO4 mixed salt at 550 °C. The corrosion resistance of each cladding layer was tested by weight loss method, and the phase compositions and microstructures of the cladding layers and corrosion products were determined by X-ray diffraction (XRD) and scanning electron microscopy (SEM). The results show that Si contributed to the formation of a dense chromium oxide film on the surface, and the addition of Si can significantly improve the corrosion resistance of the cladding layer at high temperature. At 550 °C, the corrosion rate of the cladding layer with 5 wt.% Si was only 38.2% of that of the cladding layer without Si. After 168 h of high-temperature corrosion, no Cr-rich oxide scale was found in the outermost layer of the Ni-Cr-Mo cladding layer without Si. When Si content was 3 wt.% and 5 wt.%, the Cr-rich oxide scale of the cladding layer was denser than that of the coating with 1 wt.% Si content.

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Ni-xCr-Mo laser-cladding coatings with varying Cr content of 10, 15, 20, 25, and 30 wt.% were fabricated using a self-assembled coaxial laser-cladding device. The H2S-induced high-temperature corrosion tests under reductive atmosphere were conducted at 500, 550, and 600 °C. Subsequently, the influence of Cr content on the microstructural evolution and corrosion resistance of the Ni-xCr-Mo coatings was investigated. The experimental results revealed that 30 wt.% Cr is the limited maximum content that forms the suitable morphology of coatings without large prominent pores and cracks during the fabrication process, and 15 wt.% Cr corresponds to the critical minimum content for excellent corrosion resistance, as implied from the variation tendency of the corrosion weight-gain curves. Moreover, a two-layer structure of the corrosion scales was observed in the Ni-xCr-Mo laser-cladding coatings, which was primarily caused by the selective corrosion between the Ni and S and Cr/Mo and O.

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The ATI 718Plus® is a creep-resistant nickel-based superalloy exhibiting high strength and excellent oxidation resistance in high temperatures. The present study is focused on multiscale 2D and 3D characterization (morphological and chemical) of the scale and the layer beneath formed on the ATI 718Plus superalloy during oxidation at 850 °C up to 4000 h in dry and wet air. The oxidized samples were characterized using various microscopic methods (SEM, TEM and STEM), energy-dispersive X-ray spectroscopy and electron diffraction. The 3D visualization of the microstructural features was achieved by means of FIB-SEM tomography. When oxidized in dry air, the ATI 718Plus develops a protective, dense Cr2O3 scale with a dual-layered structure. The outer Cr2O3 layer is composed of coarser grains with a columnar shape, while the inner one features fine, equiaxed grains. The Cr2O3 scale formed in wet air is single-layered and features very fine grains. The article discusses the difference between the structure, chemistry and three-dimensional phase distribution of the oxide scales and near-surface areas developed in the two environments. Electron microscopy/spectroscopy findings combined with the three-dimensional reconstruction of the microstructure provide original insight into the role of the oxidation environment on the structure of the ATI 718Plus at the nanoscale.

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The selection of fuel for a Combined Heat and Power (CHP) plant can vary over time. By choosing less expensive fuels, operation costs are reduced, however, cheaper fuels generally increase corrosion maintenance costs. The corrosiveness of different fuels has been studied extensively while how the current corrosion attack is influenced by corrosion history, i.e. previous deposit build-up and oxide scale formation, is less studied. This phenomenon may be referred to as a "corrosion memory" effect (Paz et al., 2017). The present work investigates the influence of addition of sulfur to the fuel on the corrosion memory through air-cooled probes in the Waste-to Energy lines at Måbjerg Energy Center (MEC) in Denmark. The results show a corrosion memory effect, i.e. as initially corrosive environment may increase the subsequent corrosion rate and vice versa.

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A new slurry cementation method was used to produce silicide-aluminide protective coatings on austenitic stainless steel 1.4541. The slurry cementation processes were carried out at temperatures of 800 and 1000 °C for 2 h with and without an additional oxidation process at a temperature of 1000 °C for 5 min. The microstructure and thickness of the coatings were studied by scanning electron microscopy (SEM). The intention was to produce coatings that would increase the heat resistance of the steel in a nitriding atmosphere. For this reason, the produced coatings were subjected to gas nitriding at a temperature of 550-570 °C in an atmosphere containing from 40 to 60% of ammonia. The nitriding was carried out using four time steps: 16, 51, 124, and 200 h, and microstructural observations using SEM were performed after each step. Analysis of the chemical composition of the aluminide coatings and reference sample was performed using wavelength (WDS) and energy (EDS) dispersive X-ray microanalysis, and phase analysis was carried out using X-ray diffraction (XRD). The resistance of the aluminide coatings in the nitriding atmosphere was found to depend strongly on the phase composition of the coating. The greatest increase in resistance to gas corrosion under nitriding atmosphere conditions was achieved using a manufacturing temperature of 1000 °C.

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The present study investigated the effect of corrosion on an Inconel 625-cladded layer using the cold metal transfer (CMT) method. The corrosion was caused by various ashes and high process temperatures. The ashes were obtained from the biomasses of mixed wood and oat straw, as well as from sewage sludge, by ashing. Long-term corrosion tests were carried out at 650 °C over a period of 1000 h. The chemical composition, mineral phases, and corrosion effects were studied by X-ray fluorescence (XRF), scanning electron microscopy equipped with energy-dispersive X-rays (SEM-EDX), and X-ray diffraction (XRD) from the surface and on the cross-section of the samples. The chemical composition of the ashes was quite different, but representative of their particular fuel. Together with the effects of the operating temperature and mass transfer, significant differences in the degree of the corrosion depth were detected for the various ashes. For the investigated samples, the corrosion mechanisms were inferred based on the identified corrosion products.

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Gaseous potassium chloride (KCl) that constitutes a relatively large portion of the combustion gas of municipal solid waste can condense on the surface of boiler heat exchanger tubes, causing severe corrosion attacks. To reduce the chlorine-induced high-temperature corrosion, sulfate-based additives have been used. In this study, a two-step numerical procedure is proposed to quickly predict the effect of the injection of sulfate-based additives on the removal of gaseous KCl. A computational fluid dynamics (CFD) simulation is first carried out to obtain the temperature distribution. Then, the thermal decomposition of sulfate additives, sulfation of gaseous KCl, and condensation of K2SO4 are calculated to predict the species concentration profiles at the temperature conditions given by the CFD simulation. After validation with a laboratory-scale experiment using [Formula: see text] , the procedure is applied to a pilot-scale boiler to examine the effects of [Formula: see text] , [Formula: see text] , and [Formula: see text] . The calculation results show that each additive has an optimal injection temperature range: approximately 800 °C for [Formula: see text] and 1000 °C for both [Formula: see text] and [Formula: see text] , which are consistent with the values reported in the literature. The expressions for the stoichiometric KCl removal efficiency of each additive are derived and compared with the calculated efficiencies.

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Growing interest in molten salts as effective high-temperature heat-transfer fluids for sustainable energy systems drives a critical need to fundamentally understand the interactions between metals and molten salts. This work utilizes the multimodal microscopy methods of synchrotron X-ray nanotomography and electron microscopy to investigate the 3D morphological and chemical evolution of two-model systems, pure nickel metal and Ni-20Cr binary alloy, in a representative molten salt (KCl-MgCl2 50-50 mol %, 800 °C). In both systems, unexpected shell-like structures formed because of the presence of more noble tungsten, suggesting a potential route of using Ni-W alloys for enhanced molten-salt corrosion resistance. The binary alloy Ni-20Cr developed a bicontinuous porous structure, reassembling functional porous metals manufactured by dealloying. This work elucidates better mechanistic understanding of corrosion in molten salts, which can contribute to the design of more reliable alloys for molten salt applications including next-generation nuclear and solar power plants and opens the possibility of using molten salts to fabricate functional porous materials.

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In this paper, a series of experiments are reported where ferrite nanoparticles were synthesized with different substitution percentages (5, 10, 15, or 20%) of Fe2+ by Co2+, Mn2+, or Ni2+ ions. Afterwards, the prepared nanoparticles were thermally treated between 50 and 500 °C in air for 24 h in order to observe how doping influences the oxidation process induced by temperature elevation and access to O2. Nanoparticles were imaged before and after thermal treatment by transmission electron microscopy and were analyzed by X-ray diffraction, vibrating sample magnetometry, and Mössbauer spectroscopy. Presented studies reveal that the amount and kind of doped transition metals (of replaced Fe2+) strongly affect the oxidation process of ferrite nanoparticles, which can govern the application possibility. Each transition element suppresses the oxidation process in comparison to pure Fe-oxides, with the highest impact seen with Ni2+.

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As more W replaced Mo in alumina-forming austenitic stainless steels, weight gain by oxidation decreased after 336 h at 1053 K. Electron microscopy revealed slower growth of scale in the presence of more numerous second phases by W addition. The retardation of oxidation was attributed to the necessary partitioning of W in front of the metal-oxide interface. The W-rich second phases interacted with growing oxides and finally transformed to fine particles of metallic W alloy within the scale.

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This paper presents the results of a thermal treatment process for magnetite nanoparticles in the temperature range of 50-500 °C. The tested magnetite nanoparticles were synthesized using three different methods that resulted in nanoparticles with different surface characteristics and crystallinity, which in turn, was reflected in their thermal durability. The particles were obtained by coprecipitation from Fe chlorides and decomposition of an Fe(acac)3 complex with and without a core-shell structure. Three types of ferrite nanoparticles were produced and their thermal stability properties were compared. In this study, two sets of unmodified magnetite nanoparticles were used where crystallinity was as determinant of the series. For the third type of particles, a Ag shell was added. By comparing the coated and uncoated particles, the influence of the metallic layer on the thermal stability of the nanoparticles was tested. Before and after heat treatment, the nanoparticles were examined using transmission electron microscopy, IR spectroscopy, differential scanning calorimetry, X-ray diffraction and Mössbauer spectroscopy. Based on the obtained results, it was observed that the fabrication methods determine, to some extent, the sensitivity of the nanoparticles to external factors.