In the context of the global energy structure transformation, concentrated solar power (CSP) technology has gained significant attention. Its future trajectory is oriented towards the construction of ultra-high temperature (700–1000 °C) power plants, aiming to enhance thermoelectric conversion efficiency and economic competitiveness. Chloride molten salts, serving as a crucial heat transfer and storage medium in the third-generation CSP system, offer numerous advantages. However, they are highly corrosive to metal materials. This paper provides a comprehensive review of the corrosion behaviors of stainless steels and high-temperature alloys in molten salts. It analyzes the impacts of factors such as temperature and oxygen, and it summarizes various corrosion types, including intergranular corrosion and hot corrosion, along with their underlying mechanisms. Simultaneously, it presents an overview of the types, characteristics, impurity effects, and purification methods of molten salts used for high-temperature heat storage and heat transfer. Moreover, it explores novel technologies such as alternative molten salts, solid particles, gases, liquid metals, and the carbon dioxide Brayton cycle, as well as research directions for improving material performance, like the application of nanoparticles and surface coatings. At present, the corrosion of metal materials in high-temperature molten salts poses a significant bottleneck in the development of CSP. Future research should prioritize the development of commercial alloy materials resistant to chloride molten salt corrosion and conduct in-depth investigations into related influencing factors. This will provide essential support for the advancement of CSP technology.

As concentrated solar power (CSP) systems evolve, the new generation of CSP systems will utilize chloride molten salts, which are cost-effective and have high operating temperatures, but are highly corrosive. In order to reduce the corrosiveness of chloride salts, we investigated the addition of different levels of Mg to chloride salts to study the effect on corrosion. In this paper, the corrosion behavior of 310S stainless steel with aluminum in high-temperature molten salt NaCl-KCl-MgCl₂ was studied. By adding different contents of magnesium corrosion inhibitor, the corrosion mechanism and the effect of the corrosion inhibitor were explored. The results show that the lowest corrosion rate of 6.623 mm/y was obtained for the aluminum-formed 310S with 0.05 wt.% Mg. However, the corrosion rate rises when the Mg content exceeds 0.05 wt.% compared to the corrosion rate of corroded specimens without Mg. Changing the added Mg content does not affect the corrosion products. For 310S stainless steel with aluminum, its corrosion inhibition was best achieved by adding 0.05 wt.% Mg to the chloride molten salt.

Molten carbonate salts are a promising candidate for next-generation concentrated solar power technology owing to their excellent heat storage and heat transfer properties. This represents overcoming several problems that structural materials exhibit, including severe corrosion and high-temperature creep. Alloys with an aluminum element are alternatives in this regard as they are highly resistant to corrosive environments. In this paper, the corrosion behavior in molten carbonates (Li₂CO₃-Na₂CO₃-K₂CO₃) and creep properties of TP347H with different aluminum contents at 650 °C were studied. The results demonstrated that the alloy corrosion rate was reduced via Al addition. The alloy with 2.5 wt.% Al exhibited the lowest corrosion rate: ~25% lower than that without Al after 1000 h of corrosion. With increasing Al content, the inner corrosion layer of the alloys transformed from a Cr-containing oxide layer to a Cr–Al-containing composite oxide layer. The addition of Al promoted the formation of a layer of continuous and dense LiFeO₂ product on the alloy surface during early corrosion stages, which prevented the carbonate from coming into direct contact with the substrate. After 1000 h of corrosion, the surface of the alloy is mainly composed of LiFeO₂ and LiCrO₂. Compared to TP347H, the added Al element enhanced the strength and elongation of TP347H at 650 °C. The TP347H containing 2 wt.% Al exhibited the best high-temperature tensile properties. When the stress was 110 MPa, the lowest steady-state creep rate of the alloy containing 2 wt.% Al was 3.61 × 10⁻⁶, and the true stress index was 5.791. This indicates that the creep mechanism was a dislocation climb assisted by lattice diffusion.

Concentrated solar power plant (CSP) technology holds significant application value in the renewable energy sector for converting solar radiation into thermal and electrical energy. As a heat storage medium for next-generation solar thermal power stations, chloride salts exhibit strong corrosive effects on structural components. To enhance corrosion resistance of the heated body in molten salt environments, Inconel 625 is modified by incorporating aluminum, which facilitates the formation of a protective oxide film. In this study, High-Aluminum Inconel 625, after cold rolling and solution treatment, was immersed in a NaCl-KCl-MgCl₂ eutectic chloride melt at 650 °C for 200 h. Post-corrosion analysis revealed the formation of an alumina layer on the surface, effectively mitigating corrosion. Increased aluminum content resulted in thicker alumina layers and the formation of oxidation products, such as Cr₂O₃, Fe₂O₃, MoO₂, and MgCr₂O₄ spinel structures, significantly enhancing the alloy’s corrosion resistance. The Inconel 625 cold-rolled plate with 5.31 wt% Al exhibited the best corrosion resistance (3510 μm/year), making it a promising candidate for use in next-generation CSP heat storage and exchange components.

Aiming to develop low-cost Mg alloys with good mechanical properties, a new Mg-6Bi-3Al-1Zn (wt.%, BAZ631) alloy having a high ultimate tensile strength of ~402 MPa and an elongation of ~15% was fabricated by single pass extrusion. The as-extruded BAZ631 alloy demonstrates an almost fully dynamic recrystallized microstructure with an average grain size of ~2.9 μm. Moreover, both nano-scale Mg₃Bi₂ and Mg₁₇Al₁₂ precipitates were found dispersed in the matrix. These excellent mechanical properties are attributed to the combined effects of grain boundary strengthening, dispersion and precipitation strengthening induced by both micro and nanoscale second phase particles, and solid-solution strengthening. This high strength and good ductile Mg-Bi based alloy without rare-earth elements addition is expected to inspire a new alloy design strategy for fabricating high performance Mg products for larger-scale industrial applications.

To address the technical challenge of balancing formability and strength in automotive aluminum alloys, this study examined an Al-4.35Mg-3.6Zn-0.2Cu alloy subjected to a combined heat-treatment schedule consisting of a two-step solution treatment (470 °C for 24 h followed by 460 °C for 30 min) and a subsequent two-step aging process (T4P: 80 °C for 12 h, followed by BH: 180 °C for 30 min). Microstructural evolution was characterized using transmission electron microscopy, and uniaxial tensile tests were performed in accordance with the GB/T 228.1-2021 standard at a strain rate of 0.2 mm/min. In the T4P condition, the matrix contained both GPI zones (~0.9 nm) and GPII zones (~1.2 nm), with no detectable T-phase precipitation. The presence of GPII zones enhanced ductility by promoting dynamic recovery after dislocation shearing, resulting in a yield strength (YS) of 178 MPa, an ultimate tensile strength (UTS) of 310 MPa, and an elongation (El) of 9%. After BH treatment, the GPII zones transformed into semi-coherent T′-Mg₃₂(AlZnCu)₄₉ precipitates (~2.4 nm), which strengthened the alloy through their semi-coherent interfaces. The retained GPII zones mitigated the loss of ductility, and the final mechanical properties reached a YS of 275 MPa, a UTS of 340 MPa, and an El of 8.5%, corresponding to a BH response of 97 MPa. Strengthening-mechanism calculations indicated that GP zones contributed approximately 120 MPa to the yield strength in the T4P state, whereas T′ precipitates contributed about 169.64 MPa after BH treatment. The calculated values agreed well with the experimental results, with a deviation of less than 3%. This study clarifies the precipitation sequence in the alloy—supersaturated solid solution → GPI zones → GPII zones → T′ phase—and establishes the relationship between microstructure and strength–ductility behavior. The findings provide theoretical guidance for the design and optimization of high-strength, high-formability aluminum alloys for automotive outer-panel applications.