Corrosion Behavior in Neutral Salt Spray Environment of High Strength Zn-Al Alloy Coated Steel Wire for Bridge Cables

doi:10.11902/1005.4537.2024.190

Journal of Chinese Society for Corrosion and protection

2025, Vol. 45

Issue (3): 827-836 DOI: 10.11902/1005.4537.2024.190

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Corrosion Behavior in Neutral Salt Spray Environment of High Strength Zn-Al Alloy Coated Steel Wire for Bridge Cables

CHEN Siyu(

), WANG Jingyu, GAO Liqiang

State Key Laboratory of Bridge Intelligent and Green Construction, China Railway Bridge Science Research Institute, Ltd., Wuhan 430050, China

Cite this article:

CHEN Siyu, WANG Jingyu, GAO Liqiang. Corrosion Behavior in Neutral Salt Spray Environment of High Strength Zn-Al Alloy Coated Steel Wire for Bridge Cables. Journal of Chinese Society for Corrosion and protection, 2025, 45(3): 827-836.

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Abstract

The corrosion kinetics and corrosion mechanism of Zn-Al alloy coated steel wire for 2100 MPa bridge cable in neutral salt spray environment were studied by means of electrochemical testing, corrosion loss measurement, scanning electron microscopy (SEM), X-ray diffractometer (XRD), ultra-depth of field microscopy (SDM) etc. The results show that the corrosion products of Zn-Al alloy coated steel wire are mainly composed of Zn(OH)₂ and Zn₅(OH)₈Cl₂·H₂O, and a small amount of Al(OH)₃and Fe₃O₄. The corrosion behavior can be divided into four stages: the dissolution process of passivated film, the dissolution process of zinc-rich phase, the dissolution process related with the transition interval of zinc-rich phase and eutectic phase, and the dissolution process of Zn-Al eutectic phase. During the test period, the polarization resistance R_p of the Zn-Al alloy coating decreases first and then increase, indicating that its corrosion resistance becomes weak first and then becomes strong. In other word, the corrosion rate of the steel wire increases first and then decreases. There is no obvious corrosion pits formed on the steel wire matrix and no red corrosion products on the surface of the sample. The regression analysis of the corrosion-time curve shows that the corrosion rate increases slowly with the extension of the test time, indicating that the corrosion products have a delaying effect on corrosion, therefore, the Zn-Al alloy coated steel wire has a good corrosion resistance in the neutral salt spray environment.

Key words: bridge cable wire Zinc-aluminum alloy coating salt spray corrosion properties general corrosion

Received: 24 June 2024 32134.14.1005.4537.2024.190

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Corresponding Authors: CHEN Siyu, E-mail: 347108347@qq.com

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https://www.jcscp.org/EN/10.11902/1005.4537.2024.190 OR https://www.jcscp.org/EN/Y2025/V45/I3/827

Fig.1 Sectional micromorphology of steel wire with zinc-aluminum alloy coating

Table 1 Chemical composition of zinc-aluminum coating on steel wire (mass fraction / %)

Fig.2 XRD pattern of zinc-aluminum alloy coating

Fig.3 Macro topographies of Zn-Al coated steel wire after neutral salt spray test for 120 h (a), 240 h (b), 360 h (c), 480 h (d), 600 h (e), 720 h (f), 840 h (g) and 960 h (h)

Fig.4 Macro topographies of Zn-Al coated steel wire after neutral salt spray test for 120 h (a), 240 h (b), 360 h (c), 480 h (d), 600 h (e), 720 h (f), 840 h (g), 960 h (h)

Fig.5 Ultradepth-of-field micrographs of Zn-Al coated steel wire after neutral salt spray test for 120 h (a), 240 h (b), 360 h (c), 480 h (d), 600 h (e), 720 h (f), 840 h (g) and 960 h (h)

Fig.6 Ultradepth-of-field micrographs of Zn-Al coated steel wire after neutral salt spray test for 120 h (a), 240 h (b), 360 h (c), 480 h (d), 600 h (e), 720 h (f), 840 h (g), 960 h (h), and then removing rust layers

Fig.7 SEM images of Zn-Al coated steel wire after neutral salt spray test for 120 h (a), 240 h (b), 360 h (c), 480 h (d), 600 h (e), 720 h (f), 840 h (g) and 960 h (h)

Fig.8 SEM images of Zn-Al coated steel wire after neutral salt spray test for 120 h (a), 240 h (b), 360 h (c), 480 h (d), 600 h (e), 720 h (f), 840 h (g), 960 h (h), and then removing rust layers

Table 2 Chemical compositions of Zn-Al coated steel wire after neutral salt spray test for different time and then removing rust layers

Fig.9 EDS analysis results of Zn-Al coated steel wire after neutral salt spray test for 120 h (a), 240 h (b), 360 h (c), 480 h (d), 600 h (e), 720 h (f), 840 h (g) and 960 h (h)

Fig.10 XRD patterns of Zn-Al coated steel wire after neutral salt spray test for 240 h (a), 360 h (b), 480 h (c), 600 h (d), 720 h (e), 840 h (f) and 960 h (g)

Fig.11 Tafel polarization curves of Zn-Al coated steel wire after neutral salt spray test for 120-480 h (a) and 480-960 h (b)

Table 3 Fitting electrochemical parameters of Zn-Al coated steel wire after salt spray test for different time

Fig.12 Electrochemical impedance diagrams of Zn-Al coated steel wire after salt spray test for different time: (a) Nyquist, (b) Bode, (c) equivalent circuit model

Table 4 Fitting data of electrochemical impedance spectroscopies dudu

Fig.13 Weight loss (a) and corrosion rate (b) curves of Zn-Al coated steel wire after salt spray corrosion for different time

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