It is well known that electrolytic zinc in aqueous solution of pH 6-12.5 has low corrosion rate, because the film of corroded zinc salt is stable, which is not dissolved and remains on the surface.
The investigation was undertaken to compare the corrosion characteristics among the following four kinds of products:
(a) Castings of electrolytic zinc.
(b) Castings of spelter containing 1% of Pb.
(c) Coating which has been galvanized in zinc bath containing natural admixture of 0.04% of Fe.
(d) Coating which has been galvanized in zinc bath containing natural admixtures of 0.04% of Fe and 1.05% of Pb.
The experiments were conducted by electrochemical method in 3% NaCl solution of pH 6-7, in which the surface film is rather stable and prevents diffusion of dissolved oxygen (the oxygen accelerates corrosion as mentioned above), and also in running water having resistivity of 7000Ω-cm.
Corrosion rate was determined by cathodic polarization curve obtained by galvanostatic method at the beginning of and at 1000hr after dipping. In addition, the change of corrosion potential with time was also measured for a long period.
As the results, it was found that the effects of iron and lead were negligibly little on all castings and coatings, for which protective film compactly adheres to the surface. Corrosion rate was about 0.1mm/year in 3% NaCl solution and 0.04mm/year in running water.
Accordingly, Corrosion resistance of galvanized steel produced by practical hot dipping (low carbon steel is used for galvanizing tank, of which a layer of lead lies at the bottom) was independent of the grade of zinc in the range of pH, where protective film was stable.
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