Surface Orientation-Dependent Corrosion Behavior of NiCr Alloys in Molten FLiNaK Salt

The corrosion behavior of NiCr alloys in molten FLiNaK salt is governed by complex Cr-F chemical interactions, necessitating a fundamental understanding for enhancing alloy performance in harsh environments. However, significant gaps remain in our understanding of the dynamic atomic-scale processes driving the progression of molten salt corrosion. This study employs reactive force field-based molecular dynamics simulations to unravel the influence of crystallographic orientation, temperature, and external electric fields on corrosion kinetics. The (100), (110), and (111) orientations of Ni_0.75Cr_0.25 alloys are evaluated at temperatures from 600 to 800 °C, with and without electric fields. Results reveal that Cr dissolution and near-surface diffusion drive pitting-like surface morphology evolution. The (110) surface shows the highest corrosion susceptibility, while the (100) and (111) surfaces exhibit greater resistance, with (111) being the most stable. The corrosion activation energy, derived from the Arrhenius relation, ranges from 0.27 to 0.41 eV, aligning well with limited experimental data yet significantly lower than bulk diffusion barriers. This finding indicates that corrosion progression is primarily a kinetically controlled near-surface process, rather than being limited by bulk diffusion as suggested in previous understanding. Additionally, electric fields perpendicular to the interface are found to asymmetrically modulate corrosion dynamics, where a positive field (+0.10 V/Å) promotes Cr dissolution. In comparison, a negative field (-0.10 V/Å) largely suppresses corrosion, which can be effectively used to mitigate corrosion. These findings, along with atomistic details into the corrosion mechanisms, offer strategic perspectives for designing corrosion-resistant materials in advanced high-temperature molten salt applications.