Behavior and Microstructural Evolution of Welded AISI 304 Steel Exposed to Solar Salt Under CSP-Relevant Conditions

While cost-effective austenitic stainless steels like AISI 304 are utilised in intermediate-temperature concentrated solar power (CSP) components, autogenous welding can compromise their structural integrity. This work investigates the corrosion behaviour of autogenous TIG-welded AISI 304 joints exposed to commercial molten solar salt at 550 °C for up to 1350 h under static conditions. Gravimetric and microstructural analyses revealed a stochastic bimodal breakaway oxidation mechanism. After an initial transient passivation regime (0–650 h) attributed to the formation of a protective Fe3O4/FeCr2O4 bi-layer, a sharp kinetic acceleration occurred. This localized breakdown was synergistically catalysed by trace chloride impurities, which triggered deep pitting along the microsegregated dendritic networks of the weld metal. Furthermore, due to severe X-ray attenuation under massive late-stage oxides, definitive proof of sensitisation was established using the standardised ASTM A262 Practice A topographic evaluation. The appearance of continuous ditch structures only in the heat-affected zone (HAZ) suggests severe intergranular anodic dissolution. This failure is thermodynamically driven by unmitigated residual tensile stresses, highlighting that the long-term reliability of these components is interpreted to be dictated by the localised, asymmetric breakdown of the weldment rather than uniform global oxidation.