Stability of Consumable Anode under Thermal Stress Field Induced via Molten Salt Electrolysis

Electrode stability is a critical determinant of the long-term operational efficiency and service life of electrochemical systems. Molten salt electrolysis technology utilizing consumable anodes offers a promising green and low-carbon pathway for the preparation of refractory metals and alloys, owing to its process simplicity, environmental friendliness, and high product purity. However, during electrolysis, the coupled thermo-mechanical fields can induce localized stress concentration in the anode, posing challenges to its structural integrity. This paper takes the electrolytic extraction of metallic zirconium using ZrC x O y anode as an example to study the stability of consumable anodes. Through a combination of experimental and simulation approaches, we systematically analyze the influence of key parameters-including anode geometry, immersion depth, and electrolysis temperature-on stability. The findings aim to provide theoretical guidance for optimizing electrolysis processes and designing robust anode structures.