Research Progress on Lead-bismuth Eutectic Corrosion Resistant Coatings

doi:10.15541/jim20250372

Abstract

Abstract:

Lead-bismuth eutectic (LBE), with its high boiling point, excellent thermal conductivity, and favorable safety properties, has become the core coolant for accelerator-driven advanced nuclear energy systems (ADANES) and lead-cooled fast reactors (LFRs). However, the coupled issues of oxidation corrosion, dissolution corrosion, and erosion corrosion induced by its high-temperature environment severely threaten the service life of structural materials, and hinder the engineering implementation of advanced nuclear technology. Surface coating technology, which enhances corrosion resistance while preserving the inherent properties of the substrate, has emerged as a key strategy to mitigate LBE corrosion. This paper provides a systematic review of research progress on corrosion-resistant coatings for nuclear applications against LBE corrosion. Starting from corrosion mechanisms, the influences of synergistic factors, including dissolved oxygen, temperature, flow velocity, and irradiation, on corrosion behavior are elucidated. Coatings are classified into three major systems, i.e. metallic, ceramic, and composite, and the corrosion resistance mechanisms, performance advantages, and failure behaviors of FeCrAl(Y), high-entropy alloys, Al₂O₃, MAX phases, and gradient composite coatings are analyzed. Research indicates that FeCrAl(Y) coatings form a continuous Al₂O₃ barrier layer through “matrix-oxide film” synergistic effect, with corrosion resistance and mechanical properties correlated to Cr and Al content. High-entropy alloy coatings suppress inward diffusion of corrosion species through lattice distortion and multi-component synergistic oxidation, yet they are susceptible to like high-temperature phase decomposition and irradiation embrittlement. Thermodynamically stable ceramic coatings like Al₂O₃ provide effective substrate protection, yet tend to fail in high-temperature environments due to amorphous crystallization, interface mismatch, and lack of self-healing. Composite-structured coatings with a gradient architecture of “metal transition layers + ceramic functional layers” present a promising approach for integrating high adhesion, high toughness, and high barrier properties. Future efforts should focus on coupled regulation of environment-composition-process, multi-factor service evaluation, and lifetime prediction models to deliver long-term reliable protection solutions for advanced nuclear energy systems.

Key words: lead-cooled fast reactor, lead-bismuth eutectic, coating, corrosion resistance, review

CLC Number:

TL34

LIU Chunfan, CHEN Ke, GE Fangfang, HUANG Qing. Research Progress on Lead-bismuth Eutectic Corrosion Resistant Coatings[J]. Journal of Inorganic Materials, 2026, 41(6): 775-786.

Figures/Tables 10

References 67

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Coating	Base material	Deposition method	Thickness/ μm	LBE corrosion test			Ref.
Coating	Base material	Deposition method	Thickness/ μm	O₂ concentration (mass fraction)	Temperature/℃	Duration/h	Ref.
FeCrAl	T91	GESA	30	10^-6%	480−600	2000	[9]
	T91	GESA	30	Saturated	400	900	[18]
	T91	LPPS/GESA	30	10^-6%/10^-8%	400−550	900	[19]
	F/M steel	MS	1.7−7.1	6.6×10⁻³%	500−650	1000	[20]
FeCrAlSi	F/M steel	MS	2.6−3.9	8.1×10⁻⁴%/1.8×10⁻³%/ 4.0×10⁻³%	500/550/600	1000	[21]
FeCrAlW_x	F/M steel	SLM	5.1	1.37×10⁻⁴%	550	500/1000/2000	[22]
FeCrAlY	F/M steel	MS	6	1.7×10⁻³%	550	40	[23]
FeCrMoWCBY	F/M steel	Arc melting	40	2.1×10^-3%	500	1000	[24]
AlCrFeMoTi	F/M steel	MS	3.6	Saturated	450-650	1000	[25]
AlCrFeMoTi	F/M steel	MS	4.1	6.04×10^-3%	650	1000	[26]
AlCrFeMoTiSi_x	F/M steel	MS	10	6.04×10^-3%	650	1000	[27]
FeCrAlTiNb	F/M steel	MS	3	1.8×10⁻³%/6.8×10⁻³%	550/650	500−1500	[28]
	F/M steel	MS	5−15	8×10^-4%	500	500	[29]
	F/M steel	MS	4.5	10⁻⁴%/10⁻⁷%	500	1000	[30]
TiNbZrMoV	F/M steel	MS	3.9	6.8×10^-3%	650	100−1000	[31]
FeAl	316L	Slurry aluminizing	48.8	10^-7%/1.8×10⁻³%	550	1500	[32]

Coating	Base material	Deposition method	Thickness/ μm	LBE corrosion test			Ref.
Coating	Base material	Deposition method	Thickness/ μm	O₂ concentration (mass fraction)	Temperature/℃	Duration/h	Ref.
FeCrAl	T91	GESA	30	10^-6%	480−600	2000	[9]
	T91	GESA	30	Saturated	400	900	[18]
	T91	LPPS/GESA	30	10^-6%/10^-8%	400−550	900	[19]
	F/M steel	MS	1.7−7.1	6.6×10⁻³%	500−650	1000	[20]
FeCrAlSi	F/M steel	MS	2.6−3.9	8.1×10⁻⁴%/1.8×10⁻³%/ 4.0×10⁻³%	500/550/600	1000	[21]
FeCrAlW_x	F/M steel	SLM	5.1	1.37×10⁻⁴%	550	500/1000/2000	[22]
FeCrAlY	F/M steel	MS	6	1.7×10⁻³%	550	40	[23]
FeCrMoWCBY	F/M steel	Arc melting	40	2.1×10^-3%	500	1000	[24]
AlCrFeMoTi	F/M steel	MS	3.6	Saturated	450-650	1000	[25]
AlCrFeMoTi	F/M steel	MS	4.1	6.04×10^-3%	650	1000	[26]
AlCrFeMoTiSi_x	F/M steel	MS	10	6.04×10^-3%	650	1000	[27]
FeCrAlTiNb	F/M steel	MS	3	1.8×10⁻³%/6.8×10⁻³%	550/650	500−1500	[28]
	F/M steel	MS	5−15	8×10^-4%	500	500	[29]
	F/M steel	MS	4.5	10⁻⁴%/10⁻⁷%	500	1000	[30]
TiNbZrMoV	F/M steel	MS	3.9	6.8×10^-3%	650	100−1000	[31]
FeAl	316L	Slurry aluminizing	48.8	10^-7%/1.8×10⁻³%	550	1500	[32]

Coating	Base material	Deposition method	Thickness/ μm	LBE corrosion test			Ref.
Coating	Base material	Deposition method	Thickness/ μm	O₂ concentration (mass fraction)	Temperature/℃	Duration/h	Ref.
Al₂O₃	316L	PLD	1	10^-8%	550	1000/4000	[33]
	CrNiFe600	Sol-Gel	10	7.88×10^-4%	500	200	[34]
	Inconel 600	Sol-Gel	10	No mention	650	100	[35]
	T91	MS	1.5	10^-6%	550	1200	[36]
	F/M steel	MS	3.3	1.79×10^-3%	550	1000	[37]
	9Cr1Mo steel	PLD	2-8	No mention	550	500	[38]
ZrO₂	F/M steel	MS	0.5	3.25×10⁻⁴%	450−650	1000	[39]
AlTiN	316L	CAIP	4.35	1.61×10^-3% (550 ℃)/3.21×10^-3% (600 ℃)	550/600	500	[40]
TiAlN	T91	HIPIMS	2.2	10^-6%	550	1200	[36]
TiAlN	WNiFe alloy	CAIP	3.7	Saturated oxygen	450	3000	[41]
TiSiN	316L	CAIP	2-2.5	2.15×10^-2%	550	500	[42]
TiC	SIMP steel	CAIP	5.1	2.0×10^-3%	600	2000	[43]
Ti₃AlC₂	Al₂O₃	MS	3	1×10^-6%	600	3200	[44]
Ti₂AlC
V₂AlC
Cr₂AlC
(CrAlTiNbV)N_x	F/M steel	MS	0.8/0.9	7.0×10^-3%	550	1200	[45]

Coating	Base material	Deposition method	Thickness/ μm	LBE corrosion test			Ref.
Coating	Base material	Deposition method	Thickness/ μm	O₂ concentration (mass fraction)	Temperature/℃	Duration/h	Ref.
Al₂O₃	316L	PLD	1	10^-8%	550	1000/4000	[33]
	CrNiFe600	Sol-Gel	10	7.88×10^-4%	500	200	[34]
	Inconel 600	Sol-Gel	10	No mention	650	100	[35]
	T91	MS	1.5	10^-6%	550	1200	[36]
	F/M steel	MS	3.3	1.79×10^-3%	550	1000	[37]
	9Cr1Mo steel	PLD	2-8	No mention	550	500	[38]
ZrO₂	F/M steel	MS	0.5	3.25×10⁻⁴%	450−650	1000	[39]
AlTiN	316L	CAIP	4.35	1.61×10^-3% (550 ℃)/3.21×10^-3% (600 ℃)	550/600	500	[40]
TiAlN	T91	HIPIMS	2.2	10^-6%	550	1200	[36]
TiAlN	WNiFe alloy	CAIP	3.7	Saturated oxygen	450	3000	[41]
TiSiN	316L	CAIP	2-2.5	2.15×10^-2%	550	500	[42]
TiC	SIMP steel	CAIP	5.1	2.0×10^-3%	600	2000	[43]
Ti₃AlC₂	Al₂O₃	MS	3	1×10^-6%	600	3200	[44]
Ti₂AlC
V₂AlC
Cr₂AlC
(CrAlTiNbV)N_x	F/M steel	MS	0.8/0.9	7.0×10^-3%	550	1200	[45]