No abstract

Porous materials with high specific surface area, high porosity, and high electrical conductivity are promising materials for functional applications, including catalysis, sensing, and energy storage. Molten salt dealloying was recently demonstrated in microwires as an alternative method to fabricate porous structures. The method takes advantage of the selective dissolution process introduced by impurities often observed in molten salt corrosion. This work further investigates molten salt dealloying in bulk Ni–20Cr alloy in both KCl–MgCl2 and KCl–NaCl salts at 700 ℃, using scanning electron microscopy, energy dispersive spectroscopy, and X-ray diffraction (XRD), as well as synchrotron X-ray nano-tomography. Micro-sized pores with irregular shapes and sizes ranging from sub-micron to several microns and ligaments formed during the process, while the molten salt dealloying was found to progress several microns into the bulk materials within 1–16 h, a relatively short reaction time, enhancing the practicality of using the method for synthesis. The ligament size increased from ~ 0.7 μm to ~ 1.3 μm in KCl–MgCl2 from 1 to 16 h due to coarsening, while remaining ~ 0.4 μm in KCl–NaCl during 16 h of exposure. The XRD analysis shows that the corrosion occurred primarily near the surface of the bulk sample, and Cr2O3 was identified as a corrosion product when the reaction was conducted in an air environment (controlled amount sealed in capillaries); thus surface oxides are likely to slow the morphological coarsening rate by hindering the surface diffusion in the dealloyed structure. 3D-connected pores and grain boundary corrosion were visualized by synchrotron X-ray nano-tomography. This study provides insights into the morphological and chemical evolution of molten salt dealloying in bulk materials, with a connection to molten salt corrosion concerns in the design of next-generation nuclear and solar energy power plants.

The use of molten salts for large-scale solar concentrated power plants and molten salt reactors has been driving the research to better understand how metals and alloys interact with the molten salt. As the metals may undergo morphological, chemical, and structural change in molten salt environments, it is critical to understand the fundamental mechanisms in these changes. In this work, we will present how we utilized synchrotron X-ray nano-tomography to better understand the 3D morphological evolution of Ni, Cr, and their alloys in molten salt. The effects of temperature and additives in the salt on the morphological evolution will be discussed. At the higher temperature, a characteristic bicontinuous structure can form from molten salt dealloying a binary alloy. [1] This contrasts to the intergranular corrosion found in the same system reacted at a lower temperature. [2] Different additives in the salt were also found to alter the morphological changes of the alloys and can create planar corrosion, percolation dealloying, or redeposition. To complement the morphological studies by X-ray nano-tomography, a suite of X-ray and electron microscopy analyses were also carried out to better understand the chemical and structural (both short-and long-range ordering) evolution. Taking it as a multimodal approach, we will discuss how we couple the analysis from synchrotron operando X-ray absorption spectroscopy, diffraction, and imaging, as well as the multiscale imaging studies from both X-ray and electron microscopy. This work was supported as part of the Molten Salts in Extreme Environments (MSEE) Energy Frontier Research Center (EFRC), funded by the U.S. Department of Energy, Office of Science. References: [1] "Formation of three-dimensional bicontinuous structures via molten salt dealloying studied in real-time by in situ synchrotron X-ray nano-tomography" Xiaoyang Liu, Arthur Ronne*, Lin-Chieh Yu, Yang Liu, Mingyuan Ge, Cheng-Hung Lin, Bobby Layne, Phillip Halstenberg, Dmitry S. Maltsev, Alexander S. Ivanov, Stephen Antonelli, Sheng Dai, Wah-Keat Lee, Shannon M. Mahurin, Anatoly I. Frenkel, James F. Wishart, Xianghui Xiao & Yu-chen Karen Chen-Wiegart* Nature Communications (2021), DOI: 10.1038/s41467-021-23598-8 [2] "Visualizing time-dependent microstructural and chemical evolution during molten salt corrosion of Ni-20Cr model alloy using correlative quasi in situ TEM and in situ synchrotron X-ray nano-tomography" Kaustubh Bawane, Xiaoyang Liu, Ruchi Gakhar, Michael Woods, Mingyuan Ge, Xianghui Xiao, Wah-Keat Lee, Philip Halstenberg, Sheng Dai, Shannon Mahurin, Simon M. Pimblott, James F. Wishart, Yu-chen Karen Chen-Wiegart*, Lingfeng He* Corrosion Science (2021), DOI: 10.1016/j.corsci.2021.109962