Corrosion Behavior of Cu-Mg Alloy Contact Wire in Controlled Humid Heat Environments

This study investigated the corrosion behavior of cold-drawn Cu-0.43 wt% Mg alloy wires, which were intended for high-speed railway contact lines, under varying temperature (30–50 °C) and relative humidity (85% and 93%) conditions in controlled humid heat environments. The corrosion resistance of the alloy wires after 48 h of humid heat testing was evaluated using electrochemical methods such as polarization curves and electrochemical impedance spectroscopy. The morphology and composition of the corrosion products were characterized using scanning electron microscopy/energy-dispersive spectroscopy (SEM/EDS), X-ray diffraction (XRD), and X-ray photoelectron spectroscopy (XPS). The results demonstrated superior corrosion resistance for specimens exposed to higher temperature and lower humidity (50 °C, 85% RH), as evidenced by lower corrosion current densities and higher film/charge transfer resistances compared to lower temperature and higher humidity conditions (30 °C, 93% RH). This enhanced resistance correlated with the formation of denser, more continuous protective corrosion films observed under high-temperature and low-humidity conditions. Surface analyses confirmed that the corrosion films consisted primarily of copper oxides (Cu2O and CuO), with only trace amounts of magnesium oxides detected, suggesting Mg played a minor role in the composition of the mature passive film under these conditions. These findings provide crucial data on the environmental degradation behavior of Cu-Mg contact wires, which is particularly relevant for applications in coastal or humid regions.