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耐候鋼銹層在大氣環境中的防護機制及其穩定化處理技術

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

  • 摘要: 耐候鋼能夠自發形成具有防護作用的銹層. 穩定致密且貼附表面的銹層能夠有效地阻礙腐蝕介質與基體的接觸,可在自然環境中發揮優異的耐腐蝕性. 本文從銹層結構、銹層成分和形成機制等方面對耐候鋼的銹層保護性能進行了闡述,討論了初期銹層的形成過程,明確了銹層復層結構的精細劃分以及各層腐蝕產物對耐候鋼耐蝕性的實際貢獻. 詳細分析了合金化元素、環境因素(鹽度、溫度、濕度、輻照等)對保護性銹層形成和穩定化的影響機制,明確了傳統的Cr、Cu、Ni等合金元素以及Sn、Mo、稀土元素等其他元素對有效腐蝕產物的形成、銹層形核、銹層致密性或粘結強度等的作用機制. 目前針對銹層耐蝕性的研究工作正在向人工智能、先進傳感器和大數據技術等新興領域擴展,但在復雜大氣環境(如海洋–工業大氣復合環境)對銹層形成的作用機制、多種合金元素共存的影響等方面還存在明顯不足. 更重要的是,由于完整穩定銹層的形成條件苛刻,在惡劣環境中甚至難以形成保護性銹層,仍然需要相應的防護措施. 詳細討論了現有的銹層穩定化處理技術,從涂膜技術、噴淋技術、銹層表面重構技術等方面闡述了現有的主要技術路線,對提升耐候鋼的可靠性、穩定性和適用性具有重要意義,高效環保的銹層穩定化處理技術將是未來重要的發展方向之一.

     

    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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