Progress in Failure Mechanisms and Modification Strategies of Nickel-Based Alloys for Molten Salt Reactors

doi:10.11900/0412.1961.2025.00407

Acta Metall Sin

2026, Vol. 62

Issue (8): 1331-1346 DOI: 10.11900/0412.1961.2025.00407

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Progress in Failure Mechanisms and Modification Strategies of Nickel-Based Alloys for Molten Salt Reactors

WANG You¹^,², CHEN Xiangyang¹^,²(

), WANG Xujia¹(

), TANG Chuntao¹, SHEN Zhao³(

), ZENG Xiaoqin³

1 Shanghai Nuclear Engineering Research & Design Institute Co. Ltd. , Shanghai 200233, China
2 Stage Key Laboratory of Materials for Advanced Nuclear Energy, Shanghai Nuclear Engineering Research & Design Institute Co. Ltd. , Shanghai 200233, China
3 School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China

Cite this article:

WANG You, CHEN Xiangyang, WANG Xujia, TANG Chuntao, SHEN Zhao, ZENG Xiaoqin. Progress in Failure Mechanisms and Modification Strategies of Nickel-Based Alloys for Molten Salt Reactors. Acta Metall Sin, 2026, 62(8): 1331-1346.

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Abstract

The molten salt reactor (MSR) is an important reactor type in Generation IV nuclear systems. However, the high-temperature, corrosive, and irradiation-coupled environment of MSRs compromises the chemical stability and service reliability of structural materials. Nickel-based alloys, featuring an fcc matrix with high thermal stability and low chemical activity, are promising candidates but remain susceptible to selective corrosion dissolution, Te-induced corrosion cracking, and irradiation-accelerated corrosion. This review summarizes the multifield-coupled failure mechanisms of Ni-based alloys for MSRs and outlines a four-dimensional modification framework of “composition optimization, secondary phase regulation, grain boundary regulation, and coating protection”. Lowering the Cr content and optimizing the Mo / W ratios collectively suppress selective dissolution; secondary phase/oxide dispersion strengthened particles trap defects and block diffusion; grain boundary engineering suppresses Te penetration by increasing the fraction of low-Σ boundaries; Ni-W or silicon carbide coatings provide terminal protection. Future efforts should focus on in situ multifield characterization, machine learning-based design, and environment-adaptive regulation of Ni-based alloys to achieve their long-term reliability and engineering application in MSRs.

Key words: nickel-based alloy molten salt reactor failure mechanism modification strategy

Received: 10 December 2025

ZTFLH:

TG146.1

Fund: National Natural Science Foundation of China(U25B20113);National Natural Science Foundation of China(52471043);Young Elite Scientist Sponsorship Program by CAST(TESS20240818);Qi Ming Xing Program of Shanghai(24YF2718700)

Corresponding Authors: CHEN Xiangyang, senior engineer, Tel: (021)61863529, E-mail: chenxiangyang3@snerdi.com.cn; WANG Xujia, professorate senior engineer, Tel: (021)61860728, E-mail: wangxj@snerdi.com.cn; SHEN Zhao, associate professor, Tel: (021)54740838, E-mail: shenzhao081@sjtu.edu.cn

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https://www.ams.org.cn/EN/10.11900/0412.1961.2025.00407 OR https://www.ams.org.cn/EN/Y2026/V62/I8/1331

Table 1 Summary of chemical reactions between common active elements and molten salt components and Gibbs free energy changes (ΔG) for reactions at 700 ^oC^[10]

Fig.1 Sequence of ΔG for fluoride formation^[11-13]

Fig.2 Top surface and cross-sectional SEM images and corresponding elemental analyses of Ni₈₀Cr₂₀, 800H, and GH3535 alloys after corrosion in molten FLiNaK salt (a1-a3) top surface SEM image (a1) and corresponding EDS elemental mappings of Ni (a2) and Cr (a3) in Ni₈₀Cr₂₀ alloy after 4.5 h corrosion at 600 ^oC^[14] (b1-b3) local cross-sectional SEM image (b1) and corresponding EDS elemental mappings of Ni (b2) and Cr (b3) in Ni₈₀Cr₂₀alloy after 4.5 h corrosion at 600 ^oC^[14] (c1-c3) cross-sectional SEM image (c1) and EPMA images showing the elemental distributions of Cr (c2) and Ni (c3) in 800H alloy after 300 h corrosion at 850 ^oC^[15] (d1-d3) cross-sectional SEM image (d1) and EPMA images showing the elemental distributions of Cr (d2) and Ni (d3) in GH3535 alloy after 300 h corrosion at 850 ^oC^[15]

Fig.3 BSE images and elemental line-scan profiles of alloy 625 after 48 h corrosion in molten FLiNaK salt containing 0.5%Te at 700 ^oC^[23] (a), EPMA image and corresponding elemental map showing Te penetration along grain boundaries after corrosion in Te-containing molten salt^[24] (b), cross-sectional morphology and EPMA elemental mappings of GH3535 alloy after 1000 h corrosion in molten FLiNaK salt containing Te at 700 ^oC^[26] (Arrows show the carbides) (c), and room-temperature tensile curves and morphologies (insets) of 304 stainless steel^[27] (w/o—without) (d1) and GH3535 alloy^[24] (d2) before and after corrosion in Te-containing molten salt

Table 2 Summary of ΔG of chemical reactions between common alloying elements, their carbides, and Te^[26]

Fig.4 Corrosion-induced cracking behaviors of 316L stainless steel under applied stress and the schematics of the stress corrosion cracking mechanism^[31]

Fig.5 Influence of irradiation coupling effect on material degradation

Table 3 Summary of corrosion depths for common alloys under irradiation-coupled molten salt corrosion ^[39,41-46]

Table 4 Corrosion test results of typical Ni-based alloys in molten FLiNaK salt at 850 ^oC for 500 h^[49]

Fig.6 Mechanisms of the secondary phase/matrix interface in enhancing corrosion and irradiation resistances^[60,62,64] (a1, a2) Cr adsorption and diffusion blocking (Fig.6a2 shows the Cr-rich shell around the particle marked by the circle in Fig.6a1)^[60] (b) helium bubble suppression^[64] (c1, c2) microstructures of NiMoCr-oxide dispersion strengthened (ODS) alloy after irradiation and molten salt exposure at different magnifications (Yellow circles mark grain boundary areas, and red circles indicate matrix regions)^[62]

Fig.7 Grain boundary evolution before (a1) and after (a2) grain boundary engineering (GBE) treatment^[25] (CSL—coincidence site lattice); SEM images and in situ orientation image microscopy (OIM) maps (insets) showing secondary carbide precipitation at random (R) grain boundaries (b1), Σ3 grain boundaries (b2), and Σ9 grain boundaries (b3)^[25]; corrosion mass loss (c1) and high-temperature stress-strain curves of GH3535 alloy after corrosion in molten 45LiCl-55KCl salt for 300 h in the solid-solution state (c2) and GBE-treated state (c3)^[70]

Table 5 Summary of typical coating systems, preparation processes, main process features, and applicable conditions^[71-75]

Fig.8 Technical roadmap for modification strategies of Ni-based alloys for molten salt reactors

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