In situ observation of initial rust formation process on carbon steel under Na2SO4 and NaCl solution films with wet/dry cycles using synchrotron radiation X-rays

Atmospheric corrosion of steel proceeds under thin electrolyte film formed by rain and dew condensation followed by wet and dry cycles. It is said that rust layer formed on steel as a result of atmospheric corrosion strongly affects the corrosion behavior of steel. The effect of environmental corrosiveness on the formation process and structure of the rust layer is, however, not clear to date. In this study, in situ observation of the rusting process of a carbon steel covered with a thin film of Na2SO4 or NaCl solution was performed under a wet/dry repeating condition by X-ray diffraction spectroscopy with white X-rays obtained from synchrotron radiation. The present in situ experiments successfully detected initial process of the rust formation. In the early cycles, the rust constituents were not well crystallized yet, but the presence of Fe(OH)2 and Fe(OH)3 was confirmed. In the subsequent cycles, two different solutions resulted in difference in preferential phase of the rust constituents. α-FeOOH was preferentially formed in the case of the Na2SO4 solution film, whereas β-FeOOH appeared only under the NaCl solution film.