Evolution of rust layers on carbon steel and weathering steel in high humidity and heat marine atmospheric corrosion

doi:10.1016/j.jmst.2019.07.054

Abstract

Abstract:

The evolution of the rust layers on carbon steel and weathering steel in high humidity and heat marine atmospheric environment was investigated by wet/dry cyclic acceleration corrosion tests in this study. The corrosion process of carbon steel and weathering steel was divided into two stages and the reasons for the changes in the corrosion rates of two steels were different. The composition phase of the inner rust layer of weathering steel was mainly goethite, whereas that of carbon steel was mainly akaganeite. Rust resistance (R_r) performed better than charge transfer resistance (R_t) in evaluating the protection performance of rust layer. As the corrosion proceeded, the evolution of the cathodic process of weathering steel was not obvious, whereas that of carbon steel was irregular.

Key words: High humidity and heat marine atmosphere, Weathering steel, Cl ion, Rust, Evolution

Yueming Fan, Wei Liu, Shimin Li, Thee Chowwanonthapunya, Banthukul Wongpat, Yonggang Zhao, Baojun Dong, Tianyi Zhang, Xiaogang Li. Evolution of rust layers on carbon steel and weathering steel in high humidity and heat marine atmospheric corrosion[J]. J. Mater. Sci. Technol., 2020, 39: 190-199.

Figures/Tables 15

Table 1 chemical compositions of CS and WS (wt%).

Steel	C	Si	Mn	P	S	Cu	Ni	Mo	Cr	Ti	Nb	V	Al
CS	0.153	0.33	1.11	0.016	0.0048	0.004	0.007	—	0.017	—	—	—	—
WS	0.035	0.25	1.50	<0.02	<0.005	0.350	0.380	0.12	0.50	<0.02	0.030	<0.02	0.025

Table 2 Peak positions of Raman spectra corresponding to the phases in the rust layers.

Phase	Peak position (cm^-1)
Lepidocrocite (γ-FeOOH)	217, 251, 655,713, 1300
Goethite (α-FeOOH)	203, 244, 300, 387, 399, 415, 480, 552, 684, 1002, 1113, 1304
Akaganeite (β-FeOOH)	308, 389, 499, 539, 609, 1410
Magnetite (Fe₃O₄)	306, 538
Hematite (Fe₂O₃)	228, 250, 294, 502, 1330
Maghemite (γ-Fe₂O₃)	Broad band between 339 and 386, 461 and 512, 671 and 717, 1430
Ferrihydrite (Fe₅HO₈·4H₂O)	Broad band between 700 and 710

Fig. 1. Corrosion gain results of CS and WS.

Table 3 Fitting results of the corrosion weight gain of CS and WS.

Steel	The first stage	The second stage
CS	y = 2.27x+0.89, (0≤x≤40), R² = 0.99	y = 1.54x+25.85, (40≤x≤60), R² = 0.99
WS	y = 1.74x+0.88, (0≤x≤40), R² = 0.99	y = 0.83x+34.50, (40≤x≤60), R² = 0.99

Fig. 2. Cross-sectional morphologies of the rust layers on CS and WS.

Fig. 3. Variation of atomic ratio of Na/Cl value in the inner and outer rust layers of CS and WS with the increase of CCT number.

Fig. 4. Evolution of the phase composition of the rust of CS and WS by XRD test: (a) CS; (b) WS.

Fig. 5. Semi-quantitative analysis of the rust layers formed on CS and WS with the increase of CCT number.

Fig. 6. Mass ratio of α/γ in the rust layers of CS and WS.

Fig. 7. Raman spectra measured on CS (a) and WS (b) (A: akaganeite, L: lepidocrocite, G: goethite, F: ferrihydrite, Ma: maghemite, H: hematite).

Fig. 8. Polarization curves of naked and rusted CS (a) and WS (b) at different CCT numbers.

Fig. 9. Bode plots of the EIS results for the rusted CS and WS at different CCT numbers: (a) impedance for CS; (b) impedance for WS; (c) phase angle for CS; (d) phase angle for WS.

Fig. 10. Equivalent electrical circuit of rusted CS and WS.

Fig. 11. Variation of Rr (a), Rt (b) and Rp-1 (reciprocal of Rp) (c) with the increase of CCT numbers in CS and WS.

Fig. 12. Schematic diagram of corrosion mechanism of CS (a-c) and WS (d-f).

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