Impact of Mechanical Arc Oscillation on the Microstructure and Durability of Welded Joints in Molten Salt Thermal Storage System

The two-tank molten salt thermal storage system is the most common storage solution in concentrated solar power (CSP) plants. Solar salt (60% NaNO₃ + 40% KNO₃) is the most widely used energy storage material in solar thermal plants. In solar tower technology, where the molten salts must operate at temperatures ranging from 290 °C to 565 °C, several issues related to tank failures have emerged in recent years, with some of these failures attributed to the welding process. The welding process of joints in 316L stainless steel (ASS) probes exposed to a moving flow of a binary mixture containing 60% NaNO₃ and 40% KNO₃ (solar salt) is analysed. The results were evaluated using scanning electron microscopy (SEM) at 120, 500, 1000, 1500, and 2300 h of exposure. It was identified that arc mechanical oscillations significantly improve the microstructural properties and geometrical characteristics of welded joints, reducing structural defects and improving corrosion resistance. The technique promotes uniform thermal distribution, refined dendrite morphology, and homogeneous alloying element distribution, resulting in lower mass loss in high-temperature molten salt environments. Additionally, oscillation welding optimises the bead geometry, with reduced wetting angles and controlled penetration, making it ideal for high-precision industrial applications and extreme environments, such as molten salt thermal storage systems.