Grain ultra-refinement–induced multilayer co-enrichment of Cr and Si in the rust layer enhances corrosion resistance of weathering steel
Source abstract
Abstract
Abstract In this work, the formation and evolution of the rust layer on coarse-grained (25.0 µm) and ultrafine-grained (0.5 µm) weathering steels were investigated through wet/dry cyclic corrosion test in 3.5 wt% NaCl solution, aiming to elucidate the synergistic effect of alloying elements Cr and Si on the corrosion resistance of weathering steel. Grain ultra-refinement enhances the electrochemical activity of weathering steel, leading to the co-enrichment of alloying elements Cr and Si within the rust layer in the form of a multilayered structure. The enrichment of Cr and Si within the rust layer results in the formation of multilayered Cr 3+ and Si 2+ compound oxides, which serve as an effective barrier against the permeation of corrosive media. In addition, the enrichment of alloying elements Cr within the rust layer facilitates the transformation of rust constituents into fine-grained α-FeOOH, contributing to the development of a stable, compact, and protective rust layer. Consequently, the rust layer formed on ultrafine-grained weathering steels exhibits excellent compactness and protectiveness, which enhances corrosion resistance and inhibits localized corrosion.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Corrosion Behavior and Inhibition · Hydrogen embrittlement and corrosion behaviors in metals · Erosion and Abrasive Machining
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (51)
Show source-provided references
1. Wang, Y. et al. Understanding the role of alloyed Cu and P in the initial rust composition of weathering steel formed in a simulated coastal-industrial atmosphere. Corros. Sci. 193, 109912 (2021).10.1016/j.corsci.2021.109912 ↗
2. Sun, M. et al. Distinct beneficial effect of Sn on the corrosion resistance of Cr-Mo low alloy steel. J. Mater. Sci. Technol. 81, 175–189 (2021).10.1016/j.jmst.2020.12.014 ↗
3. Yang, Y., Cheng, X., Zhao, J., Fan, Y. & Li, X. A study of rust layer of low alloy structural steel containing 0.1% Sb in atmospheric environment of the Yellow Sea in China. Corros. Sci. 188, 109549 (2021).10.1016/j.corsci.2021.109549 ↗
4. Jia, J., Cheng, X., Yang, X., Li, X. & Li, W. A study for corrosion behavior of a new-type weathering steel used in harsh marine environment. Constr. Build. Mater. 259, 119760 (2020).10.1016/j.conbuildmat.2020.119760 ↗
5. Diaz, I. et al. Atmospheric corrosion of Ni-advanced weathering steels in marine atmospheres of moderate salinity. Corros. Sci. 76, 348–360 (2013).10.1016/j.corsci.2013.06.053 ↗
6. Morcillo, M., Chico, B., Díaz, I., Cano, H. & de la Fuente, D. Atmospheric corrosion data of weathering steels. A review. Corros. Sci. 77, 6–24 (2013).10.1016/j.corsci.2013.08.021 ↗
7. Morcillo, M., Díaz, I., Chico, B., Cano, H. & de la Fuente, D. Weathering steels: from empirical development to scientific design. A review. Corros. Sci. 83, 6–31 (2014).10.1016/j.corsci.2014.03.006 ↗
8. Díaz, I. et al. Five-year atmospheric corrosion of Cu, Cr and Ni weathering steels in a wide range of environments. Corros. Sci. 141, 146–157 (2018).10.1016/j.corsci.2018.06.039 ↗
9. Morcillo, M., Díaz, I., Cano, H., Chico, B. & de la Fuente, D. Atmospheric corrosion of weathering steels. Overview for engineers. Part I: basic concepts. Constr. Build. Mater. 213, 723–737 (2019).10.1016/j.conbuildmat.2019.03.334 ↗
10. Yu, Q. et al. Layer-by-layer investigation of the multilayer corrosion products for different Ni content weathering steel via a novel Pull-off testing. Corros. Sci. 195, 109988 (2022).10.1016/j.corsci.2021.109988 ↗
11. Zhang, T. et al. On how the corrosion behavior and the functions of Cu, Ni and Mo of the weathering steel in environments with different NaCl concentrations. Corros. Sci. 192, 109851 (2021).10.1016/j.corsci.2021.109851 ↗
12. Yang, X. et al. A new understanding of the effect of Cr on the corrosion resistance evolution of weathering steel based on big data technology. J. Mater. Sci. Technol. 104, 67–80 (2022).10.1016/j.jmst.2021.05.086 ↗
13. Qian, Y., Ma, C., Niu, D., Xu, J. & Li, M. Influence of alloyed chromium on the atmospheric corrosion resistance of weathering steels. Corros. Sci. 74, 424–429 (2013).10.1016/j.corsci.2013.05.008 ↗
14. Sun, M. et al. Fundamental understanding on the effect of Cr on corrosion resistance of weathering steel in simulated tropical marine atmosphere. Corros. Sci. 186, 109427 (2021).10.1016/j.corsci.2021.109427 ↗
15. Zhang, T., Xu, X., Li, Y. & Lv, X. The function of Cr on the rust formed on weathering steel performed in a simulated tropical marine atmosphere environment. Constr. Build. Mater. 277, 122298 (2021).10.1016/j.conbuildmat.2021.122298 ↗
16. Zhao, J., Wang, P., Ma, H., Cheng, X. & Li, X. Essential role of Si in enhancing corrosion resistance of high strength low alloy steels in marine environment. J. Mater. Res. Technol. 30, 3328–3339 (2024).10.1016/j.jmrt.2024.04.108 ↗
17. Liu, H. et al. Essential role of element Si in corrosion resistance of a bridge steel in chloride atmosphere. Corros. Sci. 173, 108758 (2020).10.1016/j.corsci.2020.108758 ↗
18. Mejía Gómez, J. A., Antonissen, J., Palacio, C. A. & De Grave, E. Effects of Si as alloying element on corrosion resistance of weathering steel. Corros. Sci. 59, 198–203 (2012).10.1016/j.corsci.2012.03.004 ↗
19. Cheng, P., Liu, J., Huang, X., Huang, F. & Pang, T. Effect of silicon on the corrosion behaviour of 690 MPa weathering bridge steel in simulated industrial atmosphere. Constr. Build. Mater. 328, 127030 (2022).10.1016/j.conbuildmat.2022.127030 ↗
20. Ralston, K. D. & Birbilis, N. Effect of grain size on corrosion: a review. Corrosion 66, 075005 (2010).10.5006/1.3462912 ↗
21. Ralston, K. D., Birbilis, N. & Davies, C. H. J. Revealing the relationship between grain size and corrosion rate of metals. Scr. Mater. 63, 1201–1204 (2010).10.1016/j.scriptamat.2010.08.035 ↗
22. Rai, P. K., Shekhar, S. & Mondal, K. Development of gradient microstructure in mild steel and grain size dependence of its electrochemical response. Corros. Sci. 138, 85–95 (2018).10.1016/j.corsci.2018.04.009 ↗
23. Singh, S., Pandey, K. K., Bose, S. K. & Keshri, A. K. Role of surface nanocrystallization on corrosion properties of low carbon steel during surface mechanical attrition treatment. Surf. Coat. Technol. 396, 125964 (2020).10.1016/j.surfcoat.2020.125964 ↗
24. Liu, L., Li, Y. & Wang, F. Electrochemical corrosion behavior of nanocrystalline materials—a review. J. Mater. Sci. Technol. 26, 1–14 (2010).10.1016/S1005-0302(10)60001-1 ↗
25. Nishimura, T. Rust formation and corrosion performance of Si- and Al-bearing ultrafine grained weathering steel. Corros. Sci. 50, 1306–1312 (2008).10.1016/j.corsci.2008.01.025 ↗
26. Nishimura, T. Electrochemical behaviour and structure of rust formed on Si- and Al-bearing steel after atmospheric exposure. Corros. Sci. 52, 3609–3614 (2010).10.1016/j.corsci.2010.07.006 ↗
27. Wang, P. et al. Effects of grain size on the corrosion inhibition and adsorption performance of benzotriazole on carbon steel in NaCl solution. J. Mater. Sci. Technol. 217, 221–236 (2025).10.1016/j.jmst.2024.07.050 ↗
28. Fan, Y. et al. Effect of chloride ion on corrosion resistance of Ni-advanced weathering steel in simulated tropical marine atmosphere. Constr. Build. Mater. 266, 120937 (2021).10.1016/j.conbuildmat.2020.120937 ↗
29. Wang, P. et al. Study of rust layer evolution in Q345 weathering steel utilizing electric resistance probes. Corros. Sci. 225, 111595 (2023).10.1016/j.corsci.2023.111595 ↗
30. Wu, W., Dai, Z., Liu, Z., Liu, C. & Li, X. Synergy of Cu and Sb to enhance the resistance of 3%Ni weathering steel to marine atmospheric corrosion. Corros. Sci. 183, 109353 (2021).10.1016/j.corsci.2021.109353 ↗
31. Kamimura, T., Hara, S., Miyuki, H., Yamashita, M. & Uchida, H. Composition and protective ability of rust layer formed on weathering steel exposed to various environments. Corros. Sci. 48, 2799–2812 (2006).10.1016/j.corsci.2005.10.004 ↗
32. Della Rovere, C. A. et al. Characterization of passive films on shape memory stainless steels. Corros. Sci. 57, 154–161 (2012).10.1016/j.corsci.2011.12.022 ↗
33. Yuan, L. & Wang, H. M. Corrosion behaviors of a γ-toughened Cr13Ni5Si2/Cr3Ni5Si2 multi-phase ternary metal silicide alloy in NaCl solution. Electrochim. Acta 54, 421–429 (2008).10.1016/j.electacta.2008.07.056 ↗
34. Short, M. P., Ballinger, R. G. & Hänninen, H. E. Corrosion resistance of alloys F91 and Fe-12Cr-2Si in lead-bismuth eutectic up to 715°C. J. Nucl. Mater. 434, 259–281 (2013).10.1016/j.jnucmat.2012.11.010 ↗
35. Sun, R. et al. Effect of Si content on the corrosion behavior of 420 MPa weathering steel. Metals 9, 486 (2019).10.3390/met9050486 ↗
36. Idczak, R., Idczak, K. & Konieczny, R. Corrosion of polycrystalline Fe-Si alloys studied by TMS, CEMS, and XPS. Corrosion 74, 623–634 (2018).10.5006/2676 ↗
37. Wang, P. et al. Roles of grain refinement in the rust formation and corrosion resistance of weathering steels. Corros. Sci. 224, 111561 (2023).10.1016/j.corsci.2023.111561 ↗
38. Cabrera-Peña, J., Brito-Garcia, S. J., Mirza-Rosca, J. C. & Callico, G. M. Electrical equivalent circuit model prediction of high-entropy alloy behavior in aggressive media. Metals 13, 1204 (2023).10.3390/met13071204 ↗
39. Da, G. et al. Corrosion behavior of 700 MPa grade weathering steel with 4.0 wt% Ni and 5.0 wt% Cr in simulated marine atmospheric environment. Constr. Build. Mater. 414, 134790 (2024).10.1016/j.conbuildmat.2023.134790 ↗
40. Zhu, C. et al. Insight into the excellent corrosion resistance of a new type of weathering steel in high chloride environment by dissolution-diffusion-deposition-synergy model. Constr. Build. Mater. 485, 141901 (2025).10.1016/j.conbuildmat.2025.141901 ↗
41. Stratmann, M., Bohnenkamp, K. & Ramchandran, T. The influence of copper upon the atmospheric corrosion of iron. Corros. Sci. 27, 905–926 (1987).10.1016/0010-938X(87)90058-8 ↗
42. Stratmann, M. & Müller, J. The mechanism of the oxygen reduction on rust-covered metal substrates. Corros. Sci. 36, 327–359 (1994).10.1016/0010-938X(94)90161-9 ↗
43. Stratmann, M., Streckel, H., Kim, K. & Crockett, S. On the atmospheric corrosion of metals which are covered with thin electrolyte layers—Ⅲ the measurement of polarisation curves on metal surfaces which are covered by thin electrolyte layers. Corros. Sci. 30, 715–734 (1990).10.1016/0010-938X(90)90034-3 ↗
44. Refait, P. & Génin, J.-M. The mechanisms of oxidation of ferrous hydroxychloride β-Fe2(OH)3Cl in aqueous solution: the formation of akaganeite vs goethite. Corros. Sci. 39, 539–553 (1997).10.1016/S0010-938X(97)86102-1 ↗
45. Rémazeilles, C. & Refait, P. Formation, fast oxidation and thermodynamic data of Fe (II) hydroxychlorides. Corros. Sci. 50, 856–864 (2008).10.1016/j.corsci.2007.08.017 ↗
46. Alcantara, J. et al. Marine atmospheric corrosion of carbon steel: a review. Materials 10, 406 (2017).10.3390/ma10040406 ↗
47. Qian, Y. H., Niu, D., Xu, J. J. & Li, M. S. The influence of chromium content on the electrochemical behavior of weathering steels. Corros. Sci. 71, 72–77 (2013).10.1016/j.corsci.2013.03.002 ↗
48. Yamashita, M., Miyuki, H., Matsuda, Y., Nagano, H. & Misawa, T. The long term growth of the protective rust layer formed on weathering steel by atmospheric corrosion during a quarter of a century. Corros. Sci. 36, 283–299 (1994).10.1016/0010-938X(94)90158-9 ↗
49. Tanaka, H., Miyafuji, A., Ishikawa, T. & Nakayama, T. Influence of Ni(II), Cu(II) and Cr(III) on the formation, morphology and molecular adsorption properties of α-FeOOH rust particles prepared by aerial oxidation of neutral Fe(II) solutions. Adv. Powder Technol. 29, 9–17 (2018).10.1016/j.apt.2017.09.015 ↗
50. Kimura, M., Kihira, H., Ohta, N., Hashimoto, M. & Senuma, T. Control of Fe(O,OH)6 nano-network structures of rust for high atmospheric-corrosion resistance. Corros. Sci. 47, 2499–2509 (2005).10.1016/j.corsci.2005.04.005 ↗
51. Dong, B. et al. Optimize Ni, Cu, Mo element of low Cr-steel rebars in tropical marine atmosphere environment through two years of corrosion monitoring. Cem. Concr. Compos. 125, 104317 (2022).10.1016/j.cemconcomp.2021.104317 ↗