CO₂ corrosion resistance of carbon steel in relation with microstructure changes

The microstructural effects on the corrosion resistance of an API 5L X42 carbon steel in 0.5 M NaCl solution saturated with CO₂ was investigated. Four microstructures were considered: banded (B), normalized (N), quenched and tempered (Q&T), and annealed (A). Electrochemical measurements (polarization curves and electrochemical impedance spectroscopy) were coupled with surface analyses (scanning electron microscope (SEM) and X-ray photoelectron spectroscopy (XPS)) to characterize the formation of the corrosion product layers. Electrochemical results revealed that corrosion resistance increased in the following order: B < N < Q&T < A. From the polarization curves it was shown that specifically, cathodic current densities were affected by microstructural changes. SEM images indicated that ferrite dissolved earlier than cementite and a thin layer of corrosion products was deposited on the steel surface. XPS analyses revealed that this layer was composed of a mixture of iron carbonate and non-dissolved cementite. It was also found that the quantity of FeCO₃ content on the steel surface was greater for Q&T and A microstructures. These results, in agreement with the electrochemical data, indicate that the deposition mechanism of iron carbonate is closely related to the morphology of the non-dissolved cementite, determining the protective properties of the corrosion product layers.