Molten Salt Corrosion Probes With Sequential Breach Sensing

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Solution Overview

Problem

Conventional corrosion monitoring techniques in molten salt systems require physical removal of coupons, which is burdensome and impractical, hindering real-time analysis and validation of redox potential and other characteristics.

Innovation Solution

An in-situ corrosion monitoring device with probes having thinned regions that corrosively fail in series, allowing for real-time detection of corrosive failure and validation of redox potential without removing the device from the molten salt system, using sensing features to detect breaches in sealed chambers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of time

If conventional coupon-based corrosion monitoring is used, then corrosion information can be obtained, but real-time monitoring is hindered due to the need for physical removal and analysis of coupons

Engineering Contradiction:

Improvetime for corrosion analysisVSAvoidoperational complexity of coupon extraction

Core Design Contradiction:

Loss of timeVSEase of operation

Solution Approach 1:

The patent replaces the mechanical coupon extraction and physical analysis system with an electrical sensing system. Sensors embedded in the monitoring device detect corrosion-induced breaches electrically, eliminating the need for mechanical removal and physical laboratory analysis, thereby achieving real-time monitoring without operational disruption

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces sealed chambers as intermediaries between the corrosive environment and the sensing system. These chambers contain sensors that indirectly detect corrosion by measuring breaches caused by thinned region failures, allowing real-time monitoring without direct exposure of sensitive components to the corrosive molten salt

Inventive Principle:

Principle #24Intermediary (Mediator)

2Loss of information

If multiple coupons are monitored simultaneously, then comprehensive corrosion data is obtained, but system complexity and difficulty of real-time analysis increase

Engineering Contradiction:

Improvecompleteness of corrosion dataVSAvoidcomplexity of monitoring system

Core Design Contradiction:

Loss of informationVSDevice complexity

Solution Approach 1:

The patent divides the monitoring function into multiple independent sealed chambers, each containing sensors that detect breaches independently. This segmentation allows comprehensive monitoring of multiple thinned regions simultaneously while keeping each sensing unit simple and modular, facilitating easy data collection and analysis

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent combines multiple sensing functions into a single integrated monitoring device that simultaneously tracks several thinned regions. By merging the detection capabilities into one unified system with centralized data processing, the patent reduces overall system complexity while maintaining comprehensive monitoring coverage

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If thinned regions are made thinner to accelerate corrosion detection, then real-time monitoring capability is improved, but reliability of the probe structure decreases

Engineering Contradiction:

Improvereliability of corrosion detectionVSAvoidstructural strength of thinned region

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent provides structural cushioning by designing thinned regions with controlled minimum thicknesses that maintain sufficient mechanical strength while still failing at predictable corrosion rates. The sealed chambers and mounting structures provide additional structural support, cushioning the thinned regions against premature mechanical failure while allowing corrosion-induced failure to proceed at detectable rates

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables real-time monitoring of corrosion and validation of redox potential in molten salt systems, facilitating continuous assessment of system characteristics without disrupting the system operation.

Implementation Method 1

Each thinned region of the plurality of probes is configured to corrosively fail, when exposed to a corrosive environment

Methodology Applied

Scientific EffectCorrosion: Crevice Corrosion

Data Source

PatentUS12480860B2In-situ corrosion monitoring device and methods of use thereof

Publication Date: 2025.11.25 ABILENE CHRISTIAN UNIV

AI summary

A device for in-situ corrosion monitoring in a molten salt reactor system includes a mounting structure and a plurality of probes. Each probe of the plurality of probes may have a main portion and a thinned region that together define a sealed chamber with the mounting structure. Each thinned region of the plurality of probes may be configured to corrosively fail, when exposed to a corrosive environment, both: (i) before any main portion of the plurality of probes, and (ii) temporarily in series with the other thinned portions of the plurality of probes. The device may further include a plurality of sensing features corresponding to the plurality of probes, each sensing feature disposed in a respective sealed chamber of the plurality of probes. Each sensing feature may be configured to detect a breach of the respective sealed chamber caused by the corrosive failure of the thinned region.