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Understanding the Structure and Electrochemical Behavior of the Rust Layer Formed on a High-Strength Low-Alloy Structural Steel under Cyclic Exposure to Polluted Marine Atmosphere

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Abstract

The surface rust layer of ASTM A572 grade 50 high-strength low-alloy structural steel was examined under laboratory wet/dry cyclic corrosion test (CCT) conditions in a simulated polluted marine environment. According to the corrosion kinetics study, the entire corrosion process in the sample occurred in four stages, which were identified by the power law exponent, evolved phases, and electrochemical behavior of the rust layer at various stages. During the early stages of corrosion, the reduction of rust layer phases and the anodic dissolution of the steel substrate accelerated the overall corrosion rate. Variations in the corrosion rate were observed as the composition of the rust layer stabilized with increasing CCT cycle due to cracking and self-repairing of the rust layer. At higher CCT, the composition of the rust layer gradually changed from a conductive γ-FeOOH phase to a stable α-FeOOH phase. The electrochemical impedance analysis also revealed an increase in rust layer resistance as well as charge transfer resistance of side reactions such as hydrogen evolution reaction (HER). As a result, as CCT increased, corrosion resistance and thus the protective ability index increased (PAI). The defect density in the semiconducting rust layer formed at higher CCT was lower, indicating a higher level of protection. Based on the findings, a plausible mechanism of growth of the protective rust layer on the steel sample was proposed.

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The data supporting this study's findings are available from the corresponding author, upon reasonable request.

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Acknowledgments

The authors would like to thank the Steel Authority of India Limited (SAIL), Rourkela, for providing the steel samples. Acknowledgment is also due for the use of FESEM and micro-Raman facilities to SAIF, IIT Bombay. The authors are grateful to the National Facility of Texture and OIM for GI-XRD measurements.

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  1. Department of Metallurgical Engineering and Materials Science, Indian Institute of Technology Bombay, Powai, Mumbai, Maharashtra, 400076, India

    Amulya Bihari Pattnaik, Subhnit Roy, V. Srinivasa Raja & Smrutiranjan Parida

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Pattnaik, A.B., Roy, S., Raja, V.S. et al. Understanding the Structure and Electrochemical Behavior of the Rust Layer Formed on a High-Strength Low-Alloy Structural Steel under Cyclic Exposure to Polluted Marine Atmosphere. J. of Materi Eng and Perform (2024). https://doi.org/10.1007/s11665-024-09215-x

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