The corrosion mechanism of galvanised steel (GS) was systematically compared under the Wanning marine atmosphere and the Mohe extremely cold conditions through corrosion rate analysis, morphological observations, corrosion product analysis, and electrochemical measurements. The findings demonstrate a significant environmental influence on GS corrosion behaviour. GS exhibited significantly higher corrosion rates in the Wanning marine environment than in the Mohe extremely cold environment. In the Wanning marine environment, the corrosion product layer undergoes progressively densifying over time, thereby enhancing the corrosion barrier effectiveness of the zinc coating. The electrochemical migration of Cl− in marine environments promotes its adsorption onto the coating surface, subsequent dissolution, and enhanced ionic conductivity within the electrolyte film. Following 36-month exposure, Cl− infiltration through the coating initiated microstructural collapse, with subsequent corrosion rate manifesting a distinctive V-shaped trajectory, it reached a minimum value of 3.357 g·m−2·a−1 at the 24-month then increased rapidly to 26.089 g·m−2·a−1 at the 36-month. In contrast, the prevailing low temperatures in Mohe induced the progressive densification of the corrosion product layer over time, which acted as an enhanced protective barrier for GS and mitigated corrosion progression. The corrosion rate reached a minimum value of 2.286 g·m−2·a−1at the 36-month of exposure.
Abu-WardaNBedmarJGarcía-RodriguezS, et al.Effect of post-processing heat treatments on the high-temperature oxidation of additively manufactured 316L stainless steel. J Mater Res Technol2024; 29: 3465–3476.
2.
ProsekTPerssonDStoulilJ, et al.Composition of corrosion products formed on Zn–Mg, Zn–Al and Zn–Al–Mg coatings in model atmospheric conditions. Corros Sci2014; 86: 231–238.
3.
SundaresanCGhuleBDeyHC, et al.Oxidation behaviour of austenitic stainless steel 304HCu in advanced ultra supercritical (AUSC) steam and the efficacy of shot-peening treatment. Corros Sci2024; 235: 112214.
4.
ThierryDPerssonDLeG, et al.Long-term atmospheric corrosion of Zn-5%Al-coated steel and HDG during outdoor worldwide exposures. Corros Eng Sci Techn2020; 55: 520–530.
5.
CuiZLiXXiaoK, et al.Corrosion behavior of field-exposed zinc in a tropical marine atmosphere. Corrosion2014; 70: 731–748.
6.
AzevedoMAllelyCOgleK, et al.Corrosion mechanisms of Zn(Mg, Al) coated steel in accelerated tests and natural exposure: 1. The role of electrolyte composition in the nature of corrosion products and relative corrosion rate. Corros Sci2015; 90: 472–481.
7.
LiuYWangZCaoG, et al.Study on corrosion behavior of zinc exposed in coastal-industrial atmospheric environment. Mater Chem Phys2017; 198: 243–249.
8.
LiuYWangZKeW. Study on influence of native oxide and corrosion products on atmospheric corrosion of pure Al. Corros Sci2014; 80: 169–176.
9.
YinQWangZPanC. Initial corrosion behavior of pure zinc in simulated tropical marine atmosphere. Trans Nonferr Metal Soc China2018; 28: 2582–2591.
10.
SvenssonJJohanssonL. The temperature-dependence of the SO2−induced atmospheric corrosion of zinc; a laboratory study. Corros Sci1996; 38: 2225–2233.
11.
CuiTChengJSongJ, et al.Accelerated corrosion behavior of high strength aluminum alloy in simulated polar atmosphere. Equip Environ Eng2025; 22: 61–68.
12.
LengWShiXXinY, et al.Correlation of corrosion information acquired by indoor acceleration testing and by real low temperature marine atmosphere exposure in polar region for Ni-Cr-Mo-V steel. J Chin Soc Corros Prot2024; 44: 91–99.
13.
WallinderOLeygrafC. A critical review on corrosion and runoff from zinc and zinc-based alloys in atmospheric environments. Corrosion2017; 73: 1060–1077.
14.
DilerERouvellouBRioualS, et al.Characterization of corrosion products of Zn and Zn–Mg–Al coated steel in a marine atmosphere. Corros Sci2014; 87: 111–117.
15.
LiuYGuTLiuM, et al.Corrosion mechanism of a high corrosion-resistance Zn–Al–Mg coating in typical extremely harsh marine and cold environments. J Mater Res Technol2024; 33: 4290–4302.
16.
PerssonDThierryDLebozecN. Corrosion product formation on Zn55Al coated steel upon exposure in a marine atmosphere. Corros Sci2011; 53: 720–726.
17.
PerssonDThierryDKarlssonO. Corrosion and corrosion products of hot dipped galvanized steel during long term atmospheric exposure at different sites world-wide. Corros Sci2017; 126: 152–165.
18.
GuTLiuYPengC, et al.The inhibition effect of ultraviolet illumination on a simulated extremely cold atmospheric corrosion for zinc-aluminum-magnesium coating. J Mater Res Technol2023; 22: 3319–3330.
19.
MikhailovAAStrekalovPVPanchenkoYM. Atmospheric corrosion of metals in regions of cold and extremely cold climate (a review). Prot Met2008; 44: 644–659.
20.
CuiZLiXXiaoK, et al.Atmospheric corrosion of field-exposed AZ31 magnesium in a tropical marine environment. Corros Sci2013; 76: 243–256.
21.
ColeIGantherWFurmanS, et al.Pitting of zinc: observations on atmospheric corrosion in tropical countries. Corros Sci2010; 52: 848–858.
22.
LiuYCaoGWangZ, et al.Atmospheric corrosion behavior of galvanized steel at Hongyanhe Nuclear Power Station. Surf Technol2016; 45: 152–157.
23.
PanchenkoYMMarshakovAI. Long-term prediction of metal corrosion losses in atmosphere using a power-linear function. Corros Sci2016; 109: 217–229.
24.
YaoWCaiY. Atmospheric corrosion performance of zinc at several selected test sits in China. Corros Sci Technol Prot2003; 15: 192–195.
25.
ZhangQWuJWangJ, et al.Corrosion behavior of weathering steel in marine atmosphere. Mater Chem Phys2003; 77: 603–608.
26.
SchürzSLuckenederGFleischanderlM, et al.Chemistry of corrosion products on Zn–Al–Mg alloy coated steel. Corros Sci2010; 52: 3271–3279.
27.
DilerERioualSLescopB, et al.Chemistry of corrosion products of Zn and MgZn pure phases under atmospheric conditions. Corros Sci2012; 65: 178–186.
28.
HoskingNStroemMShipwayP, et al.Corrosion resistance of zinc–magnesium coated steel. Corros Sci2007; 49: 3669–3695.
29.
LiMDongNShangT, et al.Study on initial corrosion behavior of Zn-Al-Mg coating and pure zinc coating in typical atmospheric environment. Surf Technol2024; 53: 120–129.
30.
LiuSSunHSunL, et al.Effects of pH and Cl concentration on corrosion behavior of the galvanized steel in simulated rust layer solution. Corros Sci2012; 65: 520–527.
31.
LiXCaoGGuoM, et al.Influence of Cl− and SO2 on carbon steel Q235, pipeline steel L415 and pressure vessel steel 16MnNi corrosion behavior in industrial and marine atmosphere environment. Int J Electrochem Sci2021; 16: 21126.
32.
LiuY. Corrosion behavior of galvanized steels in Cl-containing acid rain atmospheric environment. Graduate University of Chinese Academy of Sciences, Shenyang, China, 2015.
33.
AokiIBernardMTorresiS, et al.AC-impedance and Raman spectroscopy study of the electrochemical behaviour of pure aluminium in citric acid media. Electrochim Acta2002; 46: 1871–1878.
34.
ZhangXZouDZhouY, et al.Effect of Cl-concentration on pitting corrosion property of maraging hardened stainless steel based on Pourbaix diagram. Mater Sci Forum2018; 940: 59–64.
35.
StoulilJNazarovAOswaldJ, et al.Electrochemical properties of corrosion products formed on Zn-Mg, Zn-Al and Zn-Al-Mg coatings in model atmospheric conditions. Mater Corros2015; 66: 777–782.
36.
BarsoukovEMacdonaldRJ. Impedance spectroscopy: theory, experiment, and applications. J Am Chem Soc2005; 127: 12431.
37.
WangMQiaoCJiangX, et al.Microstructure induced galvanic corrosion evolution of SAC305 solder alloys in simulated marine atmosphere. J Mater Sci Technol2020; 51: 40–53.
38.
ThierryDPerssonDLuckenederG, et al.Atmospheric corrosion of ZnAlMg coated steel during long term atmospheric weathering at different worldwide exposure sites. Corros Sci2018; 148: 338–354.
39.
OdnevallILeygrafC. Formation of NaZn4Cl(OH)6SO4·6H2O in a marine atmosphere. Corros Sci1993; 34: 1213–1229.
40.
SvenssonEJohanssonG. ChemInform abstract: laboratory study of the initial stages of the atmospheric corrosion of zinc in the presence of NaCl; influence of SO2 and NO2. Corros Sci1993; 34: 721–740.
41.
LebozecNThierryDPeltolaA, et al.Corrosion performance of Zn–Mg–Al coated steel in accelerated corrosion tests used in the automotive industry and field exposures. Mater Corros2013; 64: 969–978.
42.
OdnevallILeygrafC. The formation of Zn4Cl2(OH)4SO4·5H2O in an urban and an industrial atmosphere. Corros Sci1994; 36: 1551–1559.
43.
AzmatNRalstonKMuddleB, et al.Corrosion of Zn under acidified marine droplets. Corros Sci2011; 53: 1604–1615.
