Corrosion kinetics and patina evolution of galvanized steel in a simulated coastal-industrial atmosphere

doi:10.1016/j.jmst.2019.05.039

Abstract

Abstract:

The corrosion kinetics and patina (corrosion products) layer evolution of galvanized steel submitted to wet/dry cyclic corrosion test in a simulated coastal-industrial atmosphere was investigated. The results show that zinc coating has a greater corrosion rate during the initial period and a lower corrosion rate during the subsequent period, and the patina composition and structure can greatly affect the corrosion kinetics evolution of zinc coating. Moreover, Zn₅(OH)₆(CO₃)₂ and Zn₄(OH)₆SO₄ are identified as the main stable composition and exhibit an increasing relative amount; while Zn₁₂(OH)₁₅Cl₃(SO₄)₃ cannot stably exist and diminish in the patina layer as the corrosion develops.

Key words: Zinc, Galvanized steel, EIS, Atmospheric corrosion, Patina layer

Chuang Qiao, Lianfeng Shen, Long Hao, Xin Mu, Junhua Dong, Wei Ke, Jing Liu, Bo Liu. Corrosion kinetics and patina evolution of galvanized steel in a simulated coastal-industrial atmosphere[J]. J. Mater. Sci. Technol., 2019, 35(10): 2345-2356.

Figures/Tables 14

Fig. 1. Thickness loss and average corrosion rate of galvanized steel in simulated coastal-industrial atmosphere as a function of CCT cycle: (a) linear coordinates plot; (b) log-log coordinates plot [34].

Fig. 2. Evolution of instantaneous corrosion rate of galvanized steel in simulated coastal-industrial atmosphere as a function of CCT cycle.

Fig. 3. Evolution in the cross-sectional morphology of the patina layer on galvanized steel as a function of CCT cycle: (a) 10 CCT, (b) 20 CCT, (c) 40 CCT, (d) 60 CCT, (e) 90 CCT, (f) 120 CCT.

Fig. 4. Surface morphology observation and EDS characterization of the patina layer on galvanized steel as a function of CCT cycle: (a) 10 CCT, (b) 60 CCT, (c) 120 CCT; (a′), (b′) and (c′) corresponding to EDS spectra of the patina labelled as a, b, and c, respectively in Fig. 4(a).

Fig. 5. Synchrotron radiation XRD patterns of the powdered corrosion product on galvanized steel in simulated coastal-industrial atmosphere as a function of CCT cycle.

Fig. 6. FTIR characterization of the powdered corrosion product on galvanized steel in simulated coastal-industrial atmosphere as a function of CCT cycle.

Fig. 7. Raman spectra characterization of the powdered corrosion product on galvanized steel in simulated coastal-industrial atmosphere at 10 CCT cycle.

Table 1 Raman shift (cm-1) data for zinc corrosion products [[45], [46], [47], [48], [49]].

ZnO	Zn(OH)₂	ZnSO₄	Zn₅(OH)₆(CO₃)₂	Zn₄(OH)₆SO₄	Zn₅(OH)₈Cl₂·H₂O
[48]	[49]	[45]	[45,47]	[45,46]	[45,46]
101				395
	150
	210	218	227		210
	250	244	231		255
		278	272		267
	370		346
380		388			395
407	380		385	403
		421
437		445		451	467
		472
574		507			543
583		610		601
		626	636	620
	720		707		730
	760		736
		985	980	965	910
	1030	1022		1005
	1050	1071	1062		1065
	1080	1084	1078	1130
				1150

Fig. 8. EPMA mapping of S and Cl elements in the patina layer on galvanized steel in simulated coastal-industrial atmosphere as a function of CCT cycle.

Fig. 9. Potentiodynamic polarization curves of the un-corroded and corroded galvanized steel in the coastal-industrial atmosphere-simulating electrolyte as a function of CCT cycle.

Table 2 The evolution of fitted parameters from potentiodynamic polarization curves of un-corroded and corroded galvanized steel as the function of CCT cycle.

CCT cycle (N)	β_a (V·dec^-1)	β_c (V·dec^-1)	E_corr (V vs. SCE)	i_corr (A·cm^-2)
0 CCT	0.0544	0.5467	-1.005	2.85 × 10^-6
20 CCT	0.0695	0.0570	-1.042	1.36 × 10^-6
40 CCT	0.0860	0.1575	-1.055	1.31 × 10^-6
60 CCT	0.1035	0.1642	-1.064	8.93 × 10^-7
90 CCT	0.2059	0.1740	-1.123	4.00 × 10^-7
120 CCT	0.1336	0.1535	-1.119	4.10 × 10^-7

Fig. 10. Bode plots of EIS results for the un-corroded and corroded galvanized steel as a function of CCT cycle: (a) impedance module plot; (b) phase angle plot.

Fig. 11. Equivalent circuit used to fit the EIS data of corroded galvanized steel samples with different CCT cycle.

Fig. 12. Evolution in the fitting parameters of (a) RZHS and QZHS, (b) RHZ and QHZ, (c) Rdl and Qct obtained from EIS data of corroded galvanized steel samples as a function of CCT cycle.

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