Molten salt is one of the promising medium materials for molten salt reactors and energy storage systems. Molten salt is advantageous for better physical properties such as low melting point and high boiling point, high energy capacity, high thermal conductivity, and high thermal stability than other medium materials such as water or liquid metals. However, the corrosivity of the molten salt is one of the main factors that disturbs the various applications of the molten salt. On the other hand, metallic 3-D printing technologies have developed by leaps and bounds over the past 20 years and show potential for use in cutting-edge industries such as aerospace and military purposes. However, the biggest problem of 3-D printed products is that the mechanical and physical properties are very weak along the laminated plane that was generated during the manufacturing process. In particular, other research showed that corrosion is vulnerable through the laminated surface, and corrosion along the laminated plane is not completely mitigated through a general heat treatment process although the microstructure of the surface is evaluated to be partially mitigated by the heat treatment. In this study, molten salt corrosion behaviors of simple Ni-based alloy with a composition of 80Ni- 20Cr were analyzed. Ni-based alloys were fabricated by casting and 3-D printing, and some of the 3-D printed specimens were thermally treated at 1,273 K for 1 hour to examine the effects of heat treatment on corrosion behaviors. In molten eutectic NaCl-MgCl2 melts at 973 K, Ni-based alloys were corroded for 1, 3, 7, and 28 days and their microstructural changes were analyzed by SEM-EBSD-EDS and OM. The corrosion behaviors of the alloy were also evaluated by the salt composition measured with ICPOES. 3-D printed alloy with post-treatment showed more resistivity to the molten salt corrosion than as-fabricated 3-D printed alloy. However, the corrosion rate of the 3-D printed specimen after heat treatment was still higher than that made by casting.

In molten salt reactor (MSR), liquid fuel integrated with the molten salt coolant is used to improve the safety, resulting in the prevention of the loss-of-coolant accident (LOCA) that can occur in a pressurized water reactor (PWR). Because the structural materials used in MSRs are directly contacted with liquid fuel for a long time, they must have excellent corrosion resistance to the molten salt. Therefore, to examine the corrosion rates for Ni-based alloys in the molten salt, the corrosion experiments for alloy 600, alloy 617, and Hastelloy N were performed under LiCl molten salt at 635°C for 100 h in a glove box under Ar environment. Through a weight loss method for the three Nibased coupons before and after the corrosion tests, we evaluated their corrosion rates. Based on the results of weight loss for each alloy, we confirmed that Hastelloy N has the excellent corrosion resistance compared to the other alloys. Furthermore, the changes in the crystal structure and surface morphology with elemental distribution for the three alloys by corrosion in LiCl molten salt were analyzed, showing the variation in surface topography and the decrease in Cr element after corrosion experiments for all coupons.

At Nuclear Power Plant (NPP), aging management is performed as part of the Periodic Safety Review (PSR) in accordance with the Nuclear Safety Act. The purpose of the aging management program (AMP) is to manage the integrity of structures, systems and components (SSCs) in NPPs over time and use. Through this, aging deterioration is mitigated to increase equipment life and secure long-term operation safety. Fuel Oil Chemistry is one of the AMPs. Through this program, aging management is performed for storage tanks, piping and other metal components that contact with diesel fuel oil. The program is focused on managing loss of material due to general, pitting, crevice, and microbiologically-influenced corrosion (MIC) and fouling that leads to corrosion of the diesel fuel tank internal surfaces. The fuel oil aging management method currently applied to NPPs in Korea measures the concentration of water and particulate contamination in the oil, analyzed the trend, and periodically cleans and inspect the inside of tanks. Among them, in monitoring MIC, a direct analysis and monitoring of the amount of microorganisms may be more effective. In this study, a method for improving the MIC monitoring system for diesel fuel oil systems was reviewed by reviewing reference documents including NUREG 1801 and examining the methods actually applied in US NPPs.

KAERI has been developing a new decontamination process that does not contain any organic chemicals in the decontamination solution and minimizes the use of ion exchange resin in the solution as a purifying step. The process is hydrazine based reductive metal ion decontamination for decommissioning (HyBRID) and consists of N2H4, H2SO4 and Cu+ ions. The primary system of the LWR is composed of materials with high corrosion resistance, such as stainless steel and Inconel, but among the materials, the feeder and header of the primary system of the PHWR are composed of carbon steel (SA106Gr.B) with low corrosion resistance. Therefore, when decontamination of PHWRs, attention should be paid to corrosion of carbon steel. Since Fe3O4, a contaminating oxide film formed on the surface of carbon steel dissolves faster than ferrite or chromite formed on the surface of Inconel or stainless steel, the base material is exposed to the solution and is corroded during decontamination. When a large amount of iron ions is eluted into the decontamination agent due to corrosion of carbon steel, not only the soundness of the base metal is adversely affected, but also the amount of decontamination waste increases. The purpose of this study is to develop inhibitors that can minimize corrosion of carbon steel when decontamination of PHWRs using the HyBRID decontamination process. CG, 570S and PP3 were selected as corrosion inhibitors. In addition, corrosion tests of carbon steel were conducted in the HyBRID solution with corrosion inhibitors. The best corrosion inhibitors and optimal operating conditions were selected, and HyBRID decontamination agents with corrosion inhibitors were much better in corrosion resistance than existing commercial decontamination agents.

Chemical environments of near-field (Engineered barrier and surrounded host rock) can influence performance of a deep geological repository. The chemical environments of near-field change as time evolves eventually reaching a steady state. During the construction of a deep geological repository, O2 will be introduced to the deep geological repository. The O2 can cause corrosion of Cu canisters, and it is important predicting remaining O2 concentration in the near-field. The remaining O2 concentration in the near field can be governed by the following two reactions: oxidation of Cu(I) from oxidation of Cu and oxidation of pyrite in bentonite and backfill materials. These oxidation reactions (Cu(I) and pyrite oxidation) can influence the performance of the deep geological repository in two ways; the first way is consuming oxidizing agents (O2) and the second way is the changing pH in the near-field and ultimately influencing on the mass transport rate of radionuclides from spent nuclear fuel (failure of canisters) to out of the engineered barrier. Hence, it is very important to know the evolution of chemical environments of near-field by the oxidation of pyrite and Cu. However, the oxidation kinetics of pyrite and Cu are different in the order of 1E7 which means the overall kinetics cannot be fully considered in the deep geological repository. Therefore, it is important to develop a simplified Cu and pyrite oxidation kinetics model based on deep geological repository conditions. Herein, eight oxidation reactions for the chemical species Cu(I) were considered to extract a simplified kinetic equation. Also, a simplified kinetics equation was used for pyrite oxidation. For future analysis, simplified chemical reactions should be combined with a Multiphysics Cu corrosion model to predict the overall lifetime of Cu canisters.

Since spent nuclear fuel (SNF) should be isolated from the human life zone for at least 106 years, deep geological disposal (DGD) is considered a strong candidate for SNF management in many countries. Therefore, a disposal canister should be nearly immune to corrosion in such a long-term storage environment. Even though copper has a low corrosion rate of a few millimeters per million years in geological environments, the corrosion resistance of the copper welds must be preferentially validated, which inevitably occurs during the sealing of the disposal canister after the SNF is loaded. This is because the weld zone is a discontinuous area of microstructure, which can accelerate uniform and localized corrosion. In this study, the microstructural characteristics of copper welds in different welding conditions such as friction stir welding, electron beam welding, cold spray, were analyzed, focusing on the formation of microstructure, which affects resistance to corrosion. In addition, the microstructure and corrosion properties of the copper weld zone manufactured by recent wire-based additive manufacturing (AM) technology were experimentally evaluated. From this preliminary test result, it was found that the corrosion characteristics of the welds produced by the AM process using wire are comparable to those of the conventional forged copper plate.

The purpose of this study was to examine whether galvanic corrosion of copper occurs by inserting a third barrier layer with a higher corrosion potential than copper between copper and cast iron when the copper layer is locally perforated by pitting or partial corrosion. A triple layer composed of copper, inserted metal, and carbon steel was manufactured by cold spray coating of inserting metal powders such as Ag, Ni, and Ti on carbon steel plate followed by Cu coating on it. First, the corrosion properties were evaluated electrochemically for each metal coating. As a result of Tafel plot anaylsis in KURT groundwater condition, the corrosion potential of Fe (-567 mV) was much lower than that of Cu (-91 mV), and the corrosion potential of Ni (-150 mV) was also lower than that of Cu. Therefore, Ni was likely to corrode before Cu. However, the corrosion current of Ni was lower than that of the Cu. In the galvanic specimen where the copper and inserting metal were exposed together, Cu-Fe was much lower corrosion potential of -446 mV, and the corrosion potential of Cu-Ti, Cu-Ni, and Cu-Ag were slightly higher than that of Cu. Therefore, it seemed that Ag, Ni, and Ti all might promote galvanic corrosion of surrounding copper when the copper layer was perforated to the inserted metal layer. If the metal insertion presented in this study operates properly, the disposal container does not need to worry about the partial corrosion or non-uniform corrosion of external copper layer.

In Korea, borated stainless steel (BSS) is used as a storage rack in spent fuel pools (SFP) to maintain the nuclear criticality of spent fuels. As the number of nuclear power plants and the corresponding amount of spent fuels increased, the density in SFP storage rack also increased. In this regard, maintaining subcriticality of spent nuclear fuels became an issue and BSS was selected as the structural material and neutron absorber for high density storage rack. Since it is difficult to replace the storage rack, corrosion resistance and neutron absorbency are required for long period. BSS is based on stainless steel 304 and is specified in the ASTM A887-89 standard depending on the boron concentration from 304B (0.20-0.29% B) to 304B7 (1.75-2.25% B). Due to the low solubility of boron in austenitic stainless steel, metallic borides such as (Fe, Cr) 2B are formed as a secondary phase. Metallic borides could cause Cr depletion near it, which could decrease the corrosion resistance of the material. In this paper, the long-term corrosion behavior of BSS and its oxide microstructures are investigated through accelerated corrosion experiment in simulated SFP conditions. Because the corrosion rate of austenitic stainless steel is known to be dependent on the Arrhenius equation, a function of temperature, the corrosion experiment is conducted by increasing the experimental temperature. Detail microstructural analysis is conducted using a scanning electron microscope, transmission electron microscope and energy dispersive spectrometer. After oxidation, a hematite structure oxide film is formed, and pitting corrosion occurs on the surface of specimens. Most of the pitting corrosion is found at the substrate surface because the corrosion resistance of the substrate, which has low Cr content, is relatively low. Also, the oxidation reaction of B in the secondary phase has the lowest Gibbs free energy compared to other elements. Furthermore, oxidation of Cr has low Gibbs free energy, which means that oxidation of B and Cr could be faster than other elements. Thus, the long-term corrosion might affect the boron content and the neutron absorption ability of the material. Using boron’s high cross-section for neutrons, the neutron absorption performance of BSS was evaluated through neutron transmission tests. The effect of the corrosion behavior of BSS on its neutron absorption performance was investigated. Samples simulated to undergo up to 60 years of degradation before corrosion through accelerated corrosion testing did not show significant changes in the neutron shielding ability before and after corrosion. This can be explained in relation to the corrosion behavior of BSS. Boron was only leached out from the secondary phase exposed on the surface, and this oxidized secondary phase corresponds to about 0.17% of the volume of the total secondary phase. This can be seen as a very small proportion compared to the total boron content and is not expected to have a significant impact on neutron absorption performance.

One of the options for spent fuel dry storage systems is to store them in canisters using metal or concrete casks close to shore. The interaction between the austenitic stainless steel and the chloride atmosphere generated from the sea creates detrimental conditions leading to chloride induced stress corrosion cracking (CISCC) in the canister. The corrosion integrity of the canister in the concrete cask is very important because the canister is sealed and used for a long period of time. A canister made of austenitic stainless steel has several welding lines on the wall and lid, which are generated during the welding process and have high residual tensile stress. The interaction between the austenitic stainless steel and the chloride atmosphere generated from the sea creates detrimental conditions leading to chloride induced stress corrosion cracking (CISCC) in the canister. The corrosion integrity of the canister in the concrete cask is very important because the canister is sealed and used for a long period of time. In order to evaluate such soundness, an accelerated test capable of simulating the CISCC crack propagation phenomenon of the canister weld is required. In this study, a test device for performing the CISCC simulation test was constructed using the DCPD device. The direct current potential drop (DCPD) technique is a widely accepted method of monitoring crack initiation and growth in controlled laboratory tests. In its simplest form it involves passing a constant current through the test piece and accurately measuring the electrical potential across the crack plane, and it is a suitable device to measure crack growth in real time. The requirements for the CISCC simulation test selected based on the literature search results include test material 316 L, load range 1.75YS, positive displacement load, and 7% MgCl2 concentration. In order to smoothly evaluate these various conditions, it was determined that it is advantageous to collect crack length data in real time using a DCPD device, rather than receiving and analyzing specimens maintained for a certain time in the chamber. Therefore, in this study, 4 types of test conditions in real time was built, and data collection on crack propagation could be performed in real time by using it.

The spent fuel storage canister is generally made of austenitic stainless-steel and has the role of an important barrier to encapsulate spent fuels and radioactive materials. Canister near coastal area has welding lines, which have high residual tensile stresses after welding process. Interaction between austenitic stainless steel and chloride environment forms detrimental condition causing chloride induced stress corrosion cracking (CISCC) in canister. Reducing or eliminating tensile stress on canister can significantly decrease probability of crack initiation. Surface stress improvement works by inducing plastic strain which results in elastic relaxation that generates compressive stresses. Surface stress improvement methods such as burnishing process can effectively prevent for CISCC of canister surfaces. In this study, burnishing treatment has been evaluated to control residual tensile stress practically applicable to atmospheric CISCC for aging management of steel canisters. Burnishing process was selected as a prevention technology to CISCC of stainless steel canisters to improve resistance of CISCC through enhancement of surface roughness and generation of compressive residual stress. SUS 316 SAW (Submerged Arc Welding) specimens were burnished with flat roller and round roller after manufactured and assembled on CNC machine using base plate. The burnishing test results showed that the surface roughness of SUS 316 SAW welded specimens after roller burnishing of pass No. 5 was improved with 85% with flat roller and 93% with round roller, individually. Surface roughness showed the best state when burnished at pressure of 115 kgf, feeding rate of 40 m/stroke and pass No. of 5 turns with round roller. The surface of SUS 316 SAW welded specimens had much high residual compressive stress than yield stress of SUS 316 materials with roller burnishing treatment, independently of kinds of roller. The surface of the welded specimen by round roller burnishing showed smaller compressive stress and deeper stress region than in the surface of flat round roller burnishing. The roller burnished canister with good surface roughness could reduce the number of crack initiation sites and the high residual compressive stress formed on the welded surface might prevent the crack initiation by reducing or eliminating tensile residual stress in the weld zone, finally leads to excellent CISCC resistance. The crack growth behavior of SUS 316 welded specimens will need to investigate to evaluate the corrosion integrity of the canister materials under chloride atmosphere according to burnishing treatment.

In order to broaden the range of application of light weight aluminum alloys, it is necessary to enhance the mechanical properties of the alloys and combine them with other materials, such as cast iron. In this study, the effects of adding small amounts of Cu and Zr to the Al-Si-Mg based alloy on tensile properties and corrosion characteristics were investigated, and the effect of the addition on the interfacial compounds layer with the cast iron was also analyzed. Although the tensile strength of the Al-Si-Mg alloy was not significantly affected by the additions of Cu and Zr, the corrosion resistance in 3.5 %NaCl solution was found to be somewhat lowered in this research. The influence of Cu and Zr addition on the type and thickness of the interfacial compounds layer formed during compound casting with cast iron was not significant, and the main interfacial compounds were identified to be Al5FeSi and Al8Fe2Si phases, as in the case of the Al-Si-Mg alloys.

Sealing treatment is a post-surface treatment of the plasma spray coating process to improve the corrosion resistance of the coating material. In this study, the effect of the sealing on the corrosion resistance and adhesive strength of the plasma spray-coated alumina coatings was analyzed. For sealing, an epoxy resin was applied to the surface of the coated specimen using a brush. The coated specimen was subjected to a salt spray test for up to 48 hours and microstructural analysis revealed that corrosion in the coating layer/base material interface was suppressed due to the resin sealing. Measurement of the adhesive strength of the specimens subjected to the salt spray test indicated that the adhesive strength of the sealed specimens remained higher than that of the unsealed specimens. In conclusion, the resin sealing treatment for the plasma spray-coated alumina coatings is an effective method for suppressing corrosion in the coating layer/base material interface and maintaining high adhesive strength.

Attempts to use the molten salt system in various aspects such as MSR or energy storage systems are increasing. However, there are limitations in the molten salt-assisted technique due to the harsh corrosiveness of the molten salt, and a more detailed study on salt-induced corrosion is needed to solve this problem. In this study, corrosion behaviors of 80Ni-20Cr alloy in various salt environments such as eutectic NaCl-MgCl2 with NiCl2, CrCl2, and EuCl3 additives were investigated. Meanwhile, the corrosion acceleration effects of 80Ni-20Cr specimens were analyzed for various ceramic materials such as SiC, Al2O3, SiO2, graphite, and BN, and metallic materials such as Ni-based alloy, Fe-based alloy, and pure metals in a molten salt environment. The experiments were conducted at 973 K for up to 28 days, and after the experiment, the microstructural change of the specimen was analyzed through SEM-EDS, and salt condition was analyzed by ICP-OES.

In this study, molten salt experiments were performed using a multi-purpose molten salt experimental loop to evaluate the corrosion and thermodynamic properties of the molten salt. The multi-purpose molten salt experimental loop is made of 1-inch austenitic 316 stainless steel, and 1/4-inch austenitic 316 stainless steel tubes were welded on the surface of a 1-inch pipe to measure temperatures of molten salt. During the experiment, the molten salt leaked due to corrosion of the welded part of the 1/4-inch tube connected to the 1-inch pipe. Therefore, the cause of corrosion damage of the leaked welded part was analyzed. The effect of NaCl-MgCl2 salt selected as the molten salt on corrosion failure was considered. And based on the operation data of molten salt experiments, the time of occurrence of the issue was estimated. Lastly, the cause of corrosion failure was estimated by comparing and analyzing the pipe shape before and after failure using SEM-EDS.

Molten chloride salts are promising candidates as a coolant for Molten Salt Reactors (MSRs) because of their low cost, high specific heat transfer, and thermal energy storage capacity. The NaCl- MgCl2 eutectic salts have enormous latent heat (430 kJ/kg) and financial advantage over other types of molten chloride salt. Despite the promise of the NaCl-MgCl2 eutectic salt, problems associated with structural material corrosion in the MSR system remain. The hygroscopicity of NaCl-MgCl2 and high MSRs operating temperature accelerate corrosion within structural alloys. Especially, MgCl2 reacts with H2O in the eutectic salt to produce HCl and Cl2, which are known to further exacerbate corrosion by the chlorination of structural materials. Therefore, several studies have worked to purify impurities associated with MgCl2, such as H2O. Thermal salt purification of NaCl-MgCl2 eutectic salt is one method that reduces HCl and Cl2 gas generation. However, MgO and MgOHCl are generated as the byproduct of thermal purification through a reaction between MgCl2 and H2O. The corrosion behavior of MgO within structural alloys after thermal treatment is not well known. This paper demonstrates corrosion behavior within structural alloy after thermal treatment at various temperature profiles of the NaCl-MgCl2 eutectic salt. According to the temperature range, MgCl2·H2O are separated at 100~200°C, and MgOHCl and HCl begin to occur at 240°C or higher. Finally, MgOHCl produces MgO and HCl at 500°C or higher temperatures. After thermal treatments, the H2O, MgOHCl, and MgO content were measured by Thermo Gravimetric Analyzer (TGA) to evaluate significant products causing corrosion. The structural materials were analyzed by the Scanning Electron Microscope-Energy Dispersive Spectroscopy (SEM-EDS) and using the mass change method to observe the type of localized corrosion, the corrosion rate, and the corrosion layer thickness. This study is possible in that it can reduce economic costs by reducing the essential use of expensive, high-purity molten salts because it is related to a substantial financial cost problem considering the amount of molten salt used in industrial sites.

Safe storage of spent nuclear fuel in deep underground repositories needs an understanding of the long-term alteration (corrosion) of metal canisters and buffer materials. We conducted a small-scale laboratory alteration tests on some metal (Cu and Fe) chips by embedding them into the compacted bentonite blocks, which were placed in anaerobic water for 1 year. Some additives like lactate, sulfate, and bacteria were separately loaded into the water to promote biochemical reactions. The bentonite blocks immersed in the water were finally dismantled after 1 year, and they showed that their alteration was insignificant. However, the Cu chip exhibited some microscopic etch pits on its surface, wherein sulfur component was slightly detected. Overall, the Fe chip was more corroded than the Cu chip under the same condition. The secondary phase of the Fe chip was locally found as carbonate materials, such as siderite (FeCO3) and calcite ((Ca, Fe)CO3). These secondary products could imply that the local carbonate production around the Fe chip may be initiated by an evolution (alteration) of bentonite and a diffusive provision of biogenic CO2 gas. These laboratory scale test results suggest that the long-term alteration (corrosion) of metal canister/bentonite blocks in the engineered barrier could be possible and may be promoted by microbial activities.

Spent nuclear fuels in Korea are temporarily stored at the nuclear power plant site and it is expected that will become saturated from 2031. Deep geological disposal in engineered barrier system (EBS) is one of the most important options for disposing spent nuclear fuel. The disposal canister is the first barrier that prevents leakage of nuclides in the spent nuclear fuel to the environment. Therefore, the corrosion behavior of the canister materials are significant factors in determining the overall disposal period. Oxygen-free copper is the most widely used material for disposal canisters, and manufacturing methods include forging, cold spray, and electro-deposition. In this study, corrosion behavior of materials that have the potential to replace oxygen-free copper manufactured using various 3D printing method were analyzed. As a result of electrochemical analysis of various materials such as copper manufactured by the Atmospheric Plasma Spray (APS) process and Inconel 718 manufactured by the Direct Energy Deposition (DED) process, the possibility of replacing oxygen-free copper was confirmed.

In Korea, borated stainless steel (BSS) is used as spent fuel pool (SFP) storage rack to maintain nuclear criticality of spent fuels. As number of nuclear power plants and corresponding number of spent fuels increased, density in SFP storage rack also increased. In this regard, maintain subcriticality of spent nuclear fuels was raised as an issue and BSS was selected as structural material and neutron absorber for high density storage rack. Because it is difficult to replace storage rack, corrosion resistance and neutron absorbency are required for long period. BSS is based on stainless steel 304 and it is specified in the ASTM A887-89 standard depending on the boron concentration from 304B (0.20-0.29% B) to 304B7 (1.75-2.25% B). Due to low solubility of boron in austenitic stainless steel, metallic borides such as (Fe, Cr)2B are formed as secondary phase metallic borides could make Cr depletion near it which could decrease the corrosion resistance of material. In this paper, long-term corrosion behavior of BSS and its oxide microstructures are investigated through accelerated corrosion experiment in simulated SFP condition. Because corrosion rate of austenitic stainless steel is known to be dependent on the Arrhenius equation, a function of temperature, corrosion experiment is conducted by increasing the experimental temperature. Detail microstructural analysis was conducted with scanning electron microscope, transmission electron microscope and energy dispersive spectrometer. After oxidation, hematite structure oxide film is formed and pitting corrosions occur on the surface of specimens. Most of pitting corrosions are found at the substrate surface because corrosion resistance of substrate, which has low Cr content, is relatively low. Also, oxidation reaction of B in the secondary phase has the lowest Gibbs free energy compared to other elements. Furthermore, oxidation of Cr has low Gibbs free energy which means that oxidation of B and Cr could be faster than other elements. Thus, the long-term corrosion might affect to boron content and the neutron absorption ability of the material.

In this study, corrosion fatigue crack propagation was investigated in pH buffer environment using the giga strength steel and its heat-affected zone, and the results were compared with theoretical model prediction. Also, the pure corrosion effect on fatigue crack propagation in a corrosive environment was compared with the modified Forman equation. As results, the average value of corrosion rate obtained as the ratio of the net corrosion-induced crack length to the total crack length under cyclic loading in the base metal and heat-affected zone under experimental loading conditions. These results exhibit a new theoretical method for corrosion fatigue crack propagation that predicts a purely corrosion effect on the behavior to be determined.