耐候钢锈层在大气环境中的防护机制及其稳定化处理技术

Protective mechanism of weathering steel rust layers in atmospheric environments and their stabilization treatment technologies

  • 摘要: 耐候钢能够自发形成具有防护作用的锈层. 稳定致密且贴附表面的锈层能够有效地阻碍腐蚀介质与基体的接触,可在自然环境中发挥优异的耐腐蚀性. 本文从锈层结构、锈层成分和形成机制等方面对耐候钢的锈层保护性能进行了阐述,讨论了初期锈层的形成过程,明确了锈层复层结构的精细划分以及各层腐蚀产物对耐候钢耐蚀性的实际贡献. 详细分析了合金化元素、环境因素(盐度、温度、湿度、辐照等)对保护性锈层形成和稳定化的影响机制,明确了传统的Cr、Cu、Ni等合金元素以及Sn、Mo、稀土元素等其他元素对有效腐蚀产物的形成、锈层形核、锈层致密性或粘结强度等的作用机制. 目前针对锈层耐蚀性的研究工作正在向人工智能、先进传感器和大数据技术等新兴领域扩展,但在复杂大气环境(如海洋–工业大气复合环境)对锈层形成的作用机制、多种合金元素共存的影响等方面还存在明显不足. 更重要的是,由于完整稳定锈层的形成条件苛刻,在恶劣环境中甚至难以形成保护性锈层,仍然需要相应的防护措施. 详细讨论了现有的锈层稳定化处理技术,从涂膜技术、喷淋技术、锈层表面重构技术等方面阐述了现有的主要技术路线,对提升耐候钢的可靠性、稳定性和适用性具有重要意义,高效环保的锈层稳定化处理技术将是未来重要的发展方向之一.

     

    Abstract: Corrosion is a major cause of steel degradation, leading to material thinning, perforation, stress concentration, and ultimately deterioration of mechanical properties that can result in engineering structure failures. Weathering steels are extensively used across various applications, such as bridges, buildings, and vehicles, and are recognized for being economical and environmentally friendly. These steels can spontaneously develop protective rust layers, which are stable, compact, and adhesive, effectively inhibiting direct contact between corrosive media and the steel substrate, thereby offering superior corrosion resistance in atmospheric environments. Ideally, the corrosion resistance of the weathering steel rust layer improves with increased exposure time, though various factors can influence this behavior. This study discusses the protective properties of rust layers from multiple perspectives, including their internal and external structure, composition, formation mechanism, the influence of environmental factors and alloying elements on corrosion resistance, and current treatment technologies for rust stabilization. The rust stabilization treatment technology has been examined from its historical development to its current state and future direction. The initial process of rust formation has been described, beginning with localized sites that gradually coalesce. The dual-layered structure of rust has been introduced, and recent studies have proposed a multi-layered structure, with the specific contribution of each layer clarified. The influence of alloying elements and environmental factors, such as salinity, temperature, humidity, and irradiation, on the formation and stabilization of protective rust layers has been discussed in detail. Additionally, the impact of traditional elements like Cr, Cu, and Ni, as well as other elements such as Sn, Mo, and rare earth elements, on the formation of effective corrosion products, the nucleation of rust layers, and the compactness and bonding strength of the rust has also been analyzed. Most alloying elements enhance the protective properties of rust layers by improving their compactness, stability, and ionic selectivity. Research into evaluating the corrosion resistance of rust layers has now expanded to include artificial intelligence, advanced sensors, and big data technologies, making studies more dynamic and efficient. However, there remains a lack of research on the effects of complex atmospheric environments (such as marine-industrial complex environments) and the influence of multiple alloying elements coexisting. Clarifying the impact of each factor is challenging due to potential synergistic effects. Moreover, the conditions required for the formation of integral and stable rust layers are very stringent, and such protective rust layers may not form in harsh environments. Therefore, appropriate protective measures are still strongly recommended. This study specifically discusses the currently available rust stabilization treatment technologies, introducing key technical approaches such as coating technology, spraying technology, and surface reconstruction of the rust layer. These methods are crucial for enhancing the reliability, stability, and applicability of weathering steels. The development of efficient and environmentally friendly rust stabilization treatment technologies represents a promising area for future research.

     

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