Initial NaCl-particle induced atmospheric corrosion of zinc—Effect of CO2 and SO2

Initial corrosion and secondary spreading effects during NaCl particle induced corrosion on zinc was explored using in situ and ex situ FTIR microspectroscopy, optical microscopy, and SEM/EDAX. The secondary spreading effect which occurs upon introduction of humid air on NaCl deposited zinc surfaces was strongly dependent on the CO2 and SO2 content of the introduced air. Ambient level of CO2 (350 ppm) resulted in a relatively low spreading effect, whereas the lower level of CO2 (<5 ppm) caused a much faster spreading over a larger area. In the presence of SO2, the secondary spreading effect was absent which could limit the cathodic process in this case. At <5 ppm CO2, the corrosion is more localized, with the formation of simonkolleite (Zn5(OH)8Cl2 · H2O), zincite (ZnO) and sodium carbonate (Na2CO3), and a larger effective cathodic area. At 350 ppm CO2, the corrosion is more general and formation of simonkolleite, hydrozincite (Zn5(OH)6(CO3)2) and sodium carbonate was observed. Sodium carbonate was mainly formed in more alkaline areas, in the inner edge of the electrolyte droplet and in the secondary spreading area. Oxidation of sulphur and concomitant sulphate formation was enhanced in the presence of NaCl particles, due to the formation of a droplet, the separation of the anodic and cathodic areas and the accompanying differences in chemical composition and pH in the surface electrolyte.