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This study investigates the influence of rust layer composition on cathodic reactions and hydrogen permeation behavior of SM490 carbon steel exposed to NaCl-containing environments. Rust layers were formed on the SM490 specimens by repeated wet/dry cycles using NaCl-containing droplets. Polarization measurements revealed that rust formation and growth enhanced the cathodic reaction. The reduction reaction of rust components, particularly FeOOH, was identified as one of the predominant contributors to this enhancement. Notably, the results indicated that, in addition to the reduction of rust components, the hydrogen evolution reaction could actively proceed on Fe3O4. Because hydrogen evolution occurs less readily on FeOOH, an increase in the Fe3O4 fraction within the rust layer should promote hydrogen evolution reactivity and consequently enhance hydrogen permeation. This correlation was confirmed by electrochemical hydrogen permeation tests. These findings provided new insights into the relationship between rust layer composition and hydrogen permeation behavior, thereby advancing mechanistic understanding of hydrogen entry processes in practical steels under atmospheric corrosion conditions.

Rights:

• Creative Commons BY Attribution 4.0 International
  

Keyword: corrosion, steel, rust, hydrogen permeation

Date published: 2026-05-14

Publisher: The Electrochemical Society

Journal:

• Journal of The Electrochemical Society (ISSN: 00134651) vol. 173 issue. 9 091502

Funding:

• ISIJ Research Promotion Grant (Ishihara/Asada Grant) from the Iron and Steel Institute of Japan
• Japan Society for the Promotion of Science JP22K14516

Manuscript type: Publisher's version (Version of record)

MDR DOI:

First published URL: https://doi.org/10.1149/1945-7111/ae6483

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Updated at: 2026-05-13 17:03:43 +0900

Published on MDR: 2026-05-13 18:32:37 +0900