Mechanisms of Secondary Spreading and Micro Droplet Formation on Steel

A new theory for secondary spreading based on the wetting theory of thin films is presented. It explains how micro droplets within the spreading zone and the primary droplet retain their shape, although connected by a thin electrolyte film and how humidity and salt concentration affect the growth rate of micro droplets. The trigger for secondary spreading, polarization or alkalization, is identified by using droplets of sodium hydroxide solution. Secondary spreading thus occurs on steel from pH 13.5 without corrosion or external polarization. The limiting pH value found explains why secondary spreading on steel only occurs when certain salts are used. The effect of the substrate is investigated by changing the microstructure of the steel. By comparing the sizes of micro droplets and micro structural phases and by scanning electron microscopy/energy-dispersive X-ray analysis measurements of the spreading zone, the existence of an electrolyte film connecting the micro droplets is supported. Ecorr potential profiles of secondary spreading droplets of sodium chloride solution on steel acquired by means of SKP are used to assess the contribution of secondary spreading to the total corrosion current, which is estimated to be low compared to that of the cathodic zone at the edge of the droplet.