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高湿环境下塔筒连接段钢材腐蚀机制与涂层优化

Corrosion mechanism and coating optimization of steel in tower connection sections under high humidity environment

  • 摘要: 针对高湿含氯环境下风机塔筒连接段易发生腐蚀减薄与强度衰减的问题,阐明Q345E钢腐蚀-力学退化的演化机制,并对典型防护涂层体系进行对比优化。选取Q345E低合金钢,通过电化学测试、力学性能分析和腐蚀产物表征,系统研究其在高湿环境下的腐蚀行为及防护涂层性能。在相对湿度95%、温度60℃、质量分数3.5%Na Cl溶液中,钢材腐蚀层厚度变化在168 h后趋缓,最终达40.4μm,腐蚀坑深度增至12.7μm。Tafel极化和EIS结果表明,腐蚀初期(0~168 h)腐蚀电流密度(Icorr)由3.4μA/cm2增至8.2μA/cm2,168 h后受腐蚀产物覆盖影响,腐蚀速率下降。对比不同防护涂层,纳米陶瓷增强热喷锌(NC-TSZ)涂层表现最佳,其电荷转移阻抗(Rct)初始值为478.2Ω·cm2,1 800 h腐蚀后仍维持在289.4Ω·cm2,下降幅度39.5%。力学测试显示,经1 800 h腐蚀后,钢材抗拉强度由510.4 MPa降至432.7 MPa,伸长率由24.5%降至14.1%,表明腐蚀导致材料脆化。研究表明,氯离子侵蚀加速风机塔筒连接段钢材的腐蚀进程,优化NC-TSZ涂层可有效提升钢材耐蚀性,从而增强风机塔筒在高湿环境下的长期服役稳定性。

     

    Abstract: To address the pronounced corrosion and strength degradation of steel in wind turbine tower connections under high-humidity chloride exposure,this study aims to elucidate the corrosion-mechanical deterioration mechanism of Q345E steel and to optimize representative protective coating systems by comparative evaluation. Q345E low alloy steel was selected to systematically study the corrosion behavior and protective coating performance in high humidity environment through electrochemical testing,mechanical property analysis and corrosion product characterization. In a Na Cl solution with a mass fraction of 3.5%,a relative humidity of 95%,a temperature of 60 ℃,the thickness variation of the steel corrosion layer slowed down after 168 h,eventually reaching 40.4 μm,and the depth of the corrosion pit increased to 12.7 μm. Tafel polarization and EIS results show that Icorrincreased from 3. 4 μA/cm2 to 8.2 μA/cm2 in the early stage of corrosion(0-168h),and the corrosion rate decreased after 168 h due to the coverage of corrosion products. Compared with different protective coatings,nano-ceramic reinforced thermal sprayed zinc(NC-TSZ) performed best,with an initial Rct value of 478. 2 Ω·cm2,and it still maintained 289. 4 Ω·cm2 after 1 800 h of corrosion,a decrease of 39.5%. Mechanical tests show that after 1 800 h of corrosion,the tensile strength of the steel dropped from 510.4 MPa to 432.7 MPa,and the elongation dropped from 24.5% to 14.1%,indicating that corrosion caused the material to become brittle. Studies have shown that chloride ion erosion accelerates the corrosion process,and optimizing the NC-TSZ coating can effectively improve the corrosion resistance of steel,thereby improving the long-term service stability of wind turbine towers under high-humidity conditions.

     

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