Correlation Analysis Between Indoor Test and Outdoor Test in Hainan Coastal Atmospheric Environment for Hot-dip Galvanized Steel

doi:10.11902/1005.4537.2025.248

Journal of Chinese Society for Corrosion and protection

2026, Vol. 46

Issue (4): 1129-1138 DOI: 10.11902/1005.4537.2025.248

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Correlation Analysis Between Indoor Test and Outdoor Test in Hainan Coastal Atmospheric Environment for Hot-dip Galvanized Steel

ZHAO Ziheng¹, LI Bo¹, YANG Zhen², QIAN Wang³, YU Hao¹, ZHANG Hao¹, YI Pan², CHEN Junhang¹, YIN Chenghui¹, XIAO Kui¹(

)

^1.Institute for Advanced Materials and Technology, University of Science and Technology Beijing, Beijing 100083, China
^2.Power Transmission and Transformation Engineering and Technology Department, State Grid Electric Power Engineering Research Institute Co. Ltd., Beijing 100055, China
^3.Fujian Sanchuan Offshore Wind Power Co. Ltd., Putian 351199, China

Cite this article:

ZHAO Ziheng, LI Bo, YANG Zhen, QIAN Wang, YU Hao, ZHANG Hao, YI Pan, CHEN Junhang, YIN Chenghui, XIAO Kui. Correlation Analysis Between Indoor Test and Outdoor Test in Hainan Coastal Atmospheric Environment for Hot-dip Galvanized Steel. Journal of Chinese Society for Corrosion and protection, 2026, 46(4): 1129-1138.

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Abstract

The corrosion behavior of hot-dip galvanized steel in the tropical marine atmosphere of the Hainan coastal area was investigated through exposure tests in the natural Hainan coastal atmospheric environment and indoor spectrum-accelerated corrosion tests. Meanwhile, a corrosion prediction model was established based on the mass loss measurement results. The corrosion morphology and phase composition of the test steel surface were characterized by scanning electron microscopy (SEM) and X-ray diffraction (XRD). The electrochemical behavior of the hot-dip galvanized steel at different test durations was also examined by electrochemical means. The results indicate that after atmospheric exposure in Hainan for 2 a and spectrum-accelerated testing for 2.5 cycles, no reddish rust products were observed on the galvanized steel surface. The primary form of corrosion was uniform corrosion of the zinc coating. The corrosion kinetics followed a power function model. The corrosion products formed on the galvanized steel by both outdoor exposure and laboratory accelerated tests consisted mainly of ZnO and Zn₅(OH)₈Cl₂·H₂O. The corrosion potential increased with test duration, while the corrosion current density continuously decreased. This demonstrates that the corrosion products formed on the surface of the hot-dip galvanized steel effectively inhibited the corrosion process, thereby providing good protectiveness for the galvanized steel. Based on the comprehensive analysis of indoor and outdoor corrosion kinetics, corrosion product composition, and electrochemical mechanisms, it follows that the results of the environmental spectrum accelerated test designed for the coastal atmospheric environment of Hainan have a good correlation with the actual exposure test results in the coastal atmospheric environment of Wenchang district of Hainan Province.

Key words: Hainan coastal atmospheric environment accelerated corrosion hot-dip galvanized steel correlation analysis corrosion prediction model

Received: 03 August 2025 32134.14.1005.4537.2025.248

ZTFLH:

TG174.3

Fund: Science and Technology Project of State Grid Corporation of China(5200-202355145A-1-1-ZN)

Corresponding Authors: XIAO Kui, E-mail: xiaokui@ustb.edu.cn

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	ZHAO Ziheng
	LI Bo
	YANG Zhen
	QIAN Wang
	YU Hao
	ZHANG Hao
	YI Pan
	CHEN Junhang
	YIN Chenghui
	XIAO Kui

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https://www.jcscp.org/EN/10.11902/1005.4537.2025.248 OR https://www.jcscp.org/EN/Y2026/V46/I4/1129

Fig.1 Accelerated test method based on Hainan coastal atmospheric environment spectrum

Fig.2 3D confocal images of hot-dip galvanized steel after removal of corrosion products following different periods of outdoor exposure: (a) 1 a, (b) 2 a, (c) 2.5 a

Fig.3 SEM micro-morphologies and XRD pattern of corrosion products of hot-dip galvanized steel surface after outdoor exposure for 1 a (a) and 2 a (b), and XRD pattern of corrosion products (c)

Fig.4 3D confocal images of corrosion products removed from hot-dip galvanized steel after different periods of environmental spectrum accelerated test: (a) 1 cyc, (b) 1.5 cyc, (c) 2 cyc

Fig.5 SEM micro-morphologies (a, b) and XRD patterns (c) of corrosion products of hot-dip galvanized steel after different cycles of environmental spectrum accelerated test: (a) 1 cyc, (b) 2 cyc

Fig.6 Comparison of corrosion kinetics variation of hot-dip galvanized steel in indoor and outdoor tests in Hainan coastal atmospheric environment

Table 1 Corrosion loss data of hot-dip galvanized steel after indoor and outdoor tests in Hainan coastal atmospheric environment

Table 2 Initial processing of corrosion weight loss data of hot-dip galvanized steel after indoor and outdoor tests in Hainan coastal atmospheric environment

Table 3 Absolute differences of corrosion mass loss data of hot-dip galvanized steel after indoor and outdoor tests in Hainan coastal atmospheric environment

Fig.7 Dynamic potential polarization curves of hot-dip galvanized steel after exposure test and environmental spectrum accelerated test in Hainan coastal atmospheric environment: (a) outdoor test, (b) accelerated test

Table 4 Fitted data of dynamic polarization curves of hot-dip galvanized steel after atmospheric exposure test in Hainan coastal area at different times

Table 5 Fitted data of dynamic polarization curves of hot-dip galvanized steel after different periods of environmental spectrum accelerated test

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