Development of Self-Passivating, High-Strength Ferritic Alloys for Concentrating Solar Power (CSP) and Thermal Energy Storage (TES) Applications

Concentrating solar power (CSP) and thermal energy storage (TES) based on molten salts still lacks economic feasibility, with the material investment costs being a major drawback. Ferritic stainless steels are a comparatively cheap class of materials that could significantly contribute to cost reductions. The addition of aluminum to ferritic steel can result in self-passivation by forming a compact Al₂O₃ top layer, which exhibits significantly higher corrosion resistance to solar salt compared to the Cr₂O₃ surface layers typically formed on expensive structural alloys for CSP and TES, such as austenitic stainless steels and Ni-base super alloys. However, to date, no ferritic stainless steel combining Al₂O₃ formation and sufficient structural strength is available. For this reason, cyclic salt corrosion tests under flowing synthetic air were carried out on seven Laves phase-forming, ferritic model alloys (17Cr2-14Al0.6-1Nb2.6-4W0.25Si), using “solar salt” (60 wt. % NaNO₃ and 40 wt. % KNO₃). The Al content was varied to investigate the influence on the precipitation of the mechanically strengthening Laves phase, as well as the impact on the formation of the Al-oxide top layer. The W and Nb contents of the alloys were increased to examine their influence on the precipitation of the Laves phase. The salt corrosion experiments demonstrated that simultaneous self-passivation against a molten salt attack and mechanical strengthening by precipitation of fine Laves phase particles is possible in novel ferritic HiperFer^{SCR (salt corrosion-resistant)} steel. Microstructural examination unveiled the formation of a compact, continuous Al₂O₃ layer on the surface of the model alloys with Al contents of 5 wt. % and higher. Furthermore, a stable distribution of fine, strengthening Laves phase precipitates was achieved in the metal matrix, resulting in a combination of molten salt corrosion resistance and potentially high mechanical strength by a combination of solid solution and precipitation strengthening. These results show that high-strength ferritic alloys are suitable for use in CSP applications.