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Research on improving the corrosion resistance of carbon steel has become a hot topic in the iron and steel field in recent years. Copper plating on the surface of carbon steel is considered an effective means to improve its corrosion resistance, but the copper-plated carbon steel material prepared by this method has the problems of poor abrasion resistance, easy delamination of copper layer and similar issues, which affect the service performance of the copper-plated carbon steel material. To solve this problem, a new type of material whose surface is copper and the copper element is gradually diffused into carbon steel was developed by a plating-diffusion method, which is defined as a copper-carbon steel gradient material. Carbon steel with a copper plated surface and the Cu-Fe/carbon steel gradient material with 80% Cu content on the surface were prepared by the same method. The cross-sectional microstructure and composition of different samples were analysed, and the corrosion behaviors of samples in 3.5% NaCl solution were studied by the linear polarization curve method and electrochemical impedance spectroscopy. The cross-sectional microstructure result shows that the diffusion of copper in carbon is mainly carried out along its grain boundary, and the diffusion of copper will inhibit the growth of grains during heat treatment. As shown in the results of corrosion behaviors, there is no pitting corrosion in the corrosion process of all samples, as well as the stable passive film. All samples showed active dissolution. Compared with carbon steel, the corrosion potential of the Cu/carbon steel gradient material becomes more positive from −600 mV to −362 mV, the corrosion current density decreases from 53.0 μA/cm2 to 30.6 μA/cm2 and the radius of electrochemical impedance spectroscopy enlarges while the corrosion resistance is improved, and the corrosion resistance is mainly obtained by its surface copper layer. The corrosion resistance of Cu-Fe/carbon steel gradient material is lower than that of Cu/carbon steel gradient material, while it is still better than carbon steel, and it shows a clear passivation trend during corrosion. Therefore, the copper/carbon steel gradient material can significantly improve the corrosion resistance of carbon steel. Even after the surface copper layer is destroyed, the gradient material can protect the matrix and improve the service life of the material.

Corrosion Behaviour of Cu/Carbon Steel Gradient Material