Salt Spray Corrosion of DH460 Steel for Offshore Converter Stations and Protectiveness of Ceramic Coatings

doi:10.11902/1005.4537.2025.233

Journal of Chinese Society for Corrosion and protection

2026, Vol. 46

Issue (4): 1257-1268 DOI: 10.11902/1005.4537.2025.233

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Salt Spray Corrosion of DH460 Steel for Offshore Converter Stations and Protectiveness of Ceramic Coatings

WANG Liuhuo¹, SUN Qiang¹, QI Han¹, HU Sukai¹, YE Huanhuan¹, LIU Jiahan², WANG Dayang³, ZHANG Tao²(

)

^1.Guangdong Power Grid Co. Ltd., Guangzhou 510699, China
^2.School of Physics and Materials, GuangZhou University, Guangzhou 510006, China
^3.School of Civil and Transportation Engineering, GuangZhou University, Guangzhou 510006, China

Cite this article:

WANG Liuhuo, SUN Qiang, QI Han, HU Sukai, YE Huanhuan, LIU Jiahan, WANG Dayang, ZHANG Tao. Salt Spray Corrosion of DH460 Steel for Offshore Converter Stations and Protectiveness of Ceramic Coatings. Journal of Chinese Society for Corrosion and protection, 2026, 46(4): 1257-1268.

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Abstract

In this paper, the salt spray corrosion resistance of DH460 steel for offshore wind power converter stations and the protective effects of ceramic coatings were investigated via neutral salt spray accelerated corrosion tests as a simulation of the realcorrosion environments in service. The tested samples and the formed corrosion products were characterized by means of scanning electron microscopy/energy-dispersive spectroscopy (SEM/EDS), X-ray diffraction (XRD), electrochemical testing, tensile testing, and fatigue testing etc. The results reveal that corrosion-induced intergranular brittle fracture reduces the mechanical properties of the steel. Based on the salt spray-mechanistic coupling test, the fatigue life of DH460 steel after salt spray test was revealed, and a failure model of “synergistic effect of corrosion product expansion stress grain boundary crack” was constructed. By designing and constructing a composite ceramic coating on the surface of DH460 steel, the resistance to salt spray corrosion of the DH460 steel has been significantly improved by the applied composite ceramic coating. Within the laboratory parameter range, no change was observed in the performance and structural integrity of the DH460 steel before and after corrosion test, indicating that the ceramic coating can completely block the entry of corrosive substances upon the steel substrate.

Key words: DH460 steel salt spray corrosion corrosion mechanism anti-corrosion coating

Received: 21 July 2025 32134.14.1005.4537.2025.233

ZTFLH:

TG174

Fund: China Southern Power Grind Compony Research Project on New Technologies for Infrastructure Construction(031751WD24050008)

Corresponding Authors: ZHANG Tao, E-mail: zhangtao@gzhu.edu.cn

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	WANG Liuhuo
	SUN Qiang
	QI Han
	HU Sukai
	YE Huanhuan
	LIU Jiahan
	WANG Dayang
	ZHANG Tao

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https://www.jcscp.org/EN/10.11902/1005.4537.2025.233 OR https://www.jcscp.org/EN/Y2026/V46/I4/1257

Fig.1 Geometry and dimensions of the tensile specimen

Fig.2 Surface morphologies of as prepared DH460 steel (a) and after corrosion for 2 d (b), 4 d (c), 6 d (d), 8 d (e) and 10 d (f)

Fig.3 Surface morphologies of DH460 steel before (a) and after (b-d) corrosion

Fig.4 XRD patterns of DH460 steel before and after corrosion

Fig.5 SEM micrographs of DH460 steel after 5%NaCl salt spray corrosion for 10 d: (a) corroded surface area, (b-d) magnified image of the area in Fig.5a

Fig.6 EDS analysis of element distribution in DH460 steel after corrosion

Fig.7 Cross-sectional SEM morphologies of DH460 steel after corrosion: (a) low magnification, (b) high magnification

Fig.8 SEM morphology of DH460 steel corrosion products (a) and EDS line scan at the corresponding location (b)

Fig.9 Comparison of stress-strain properties before and after corrosion (a), and total elongation and yield stress changes with corrosion time (b)

Fig.10 Morphologies of tensile fracture (a), ductile fracture zone near the corrosion side (b) and its magnified image (c), ductile fracture zone near the center (d) and its magnified image (e)

Fig.11 Mass loss rate of samples after different corrosion time

Fig.12 Relationship between stress (S) and fatigue life (N_f) of DH460 steel

Fig.13 Electrochemical analysis of DH460 steel before and after corrosion: (a) |Z|-frequency plots of EIS, (b) phase angle-frequency plots of EIS, (c) potentiodynamic polarization curves, (d) OCP-time curves, (e) Nyquist plots of EIS

Fig.14 Morphologies of coated DH460 steel before (a) and after (b) corrosion, corresponding line scanning region (c) and line scanning results (d)

Fig.15 Surface roughness analysis of DH460 steel: (a, b) as-cast surface; (c, d) after 10 d corrosion; (e, f) coated surface after corrosion. (a, c, e) show surface morphology, while (b, d, f) present corresponding grayscale representations

Fig.16 Comparison of corrosion depth and corrosion product

Fig.17 3D morphology and microscopic images of friction wear tracks on DH460 steel samples; (a, b) uncoated (c, d) coated protection

Fig.18 Comparison of wear scars on DH460 steel samples before and after corrosion without coating and with coating

Fig.19 Tensile curves (a) of DH460 steel samples before and after corrosion without coating and with coating, and SEM morphology of fracture zone of DH460 steel sample with coating (b)

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