Abstract
The corrosion behaviour of electrochemically induced surface annealed (EISA) 304L stainless steel was analysed using a range of electrochemical methods, such as polarisation, impedance and Mott–Schottky techniques. Secondary ion mass spectroscopy was used to examine the elemental distribution around the surface of an EISA-treated specimen. The results showed that the EISA treatment increases the resistance to pitting corrosion due to surface densification caused by the absorption of NO and/or N2, which had been reduced under cathodic polarisation during the EISA process. Owing to the limited annealing depth, however, the prolonged corrosion process (i.e. Fe dissolution) can lead to the dissolution of NO and/or N2 species, which had been absorbed on the outer surface, and only smaller portions remained with an uneven distribution at the surface. This can make the EISA-treated steel more vulnerable to corrosion.
Keywords
Introduction
Austenitic stainless steels are used widely in a variety of industrial fields, such as the petroleum, chemical and food industries, because of their superior corrosion resistance [1]. When the steels are applied in the afore-mentioned fields, a mechanical forming process is necessarily involved. Under heavily plastically deformed conditions, such as rolling and grounding, the metastable austenite matrix was transformed to martensite by mechanical-phase transformation [2 -10]. The high levels of residual stress in martensite causes degradation in the mechanical properties and corrosion resistance [11–14]. In general, heat treatment of mechanically deformed austenitic stainless steel is carried out at several hundreds of degrees Celsius to remove the martensitic phase [2]. At several hundreds of degrees, however, carbides, such as chromium carbides, can be precipitated, which result in a decrease in bulk properties, particularly the mechanical properties and corrosion resistance of steel [15–19]. Therefore, a surface treatment of steel without affecting their bulk properties is essential for a range of applications. Burstein et al. [20] proposed a novel concept of an EISA treatment to remove the martensite phase from the steel surface without altering the bulk properties of the steel. They reported that the martensite phase that had formed by a grinding process had decreased significantly after the EISA treatment involving a series of electrochemical pulses composed of anodic and cathodic overpotentials in a sodium nitrite solution. Based on the contraction of the γ-phase lattice parameter [21], they suggested that the surface annealing effect might be due to an austenite-stabilizing element, such as nitrogen. On the other hand, precise analytical evidence was not presented, and the underlying mechanism was not provided. Furthermore, the influence of EISA on the corrosion behaviours of the austenitic stainless steel is still unclear. Although Li et al. [22] evaluated the resistance of the EISA-treated stainless steel to pitting corrosion using a potentiodynamic polarisation test in a 3.5% NaCl solution, it was not enough to determine the prolonged corrosion behaviours of the steel with the limited information available. Therefore, potentiodynamic polarisation, electrochemical impedance spectroscopy (EIS), Mott–Schottky, and secondary ion mass spectroscopy (SIMS) measurements were employed to gain a better understanding of the effects of EISA treatment on the surface characteristics, including the corrosion behaviours. Based on the experimental results, a possible corrosion mechanism of the EISA-treated stainless steel in acidic environments is proposed.
Experimental
Specimen preparation
Chemical composition of the tested specimen.
EISA treatment
The surfaces were subjected to the same conditions of the EISA treatment. The surfaces were treated with a series of anodic and cathodic electrochemical pulses, −1.8 V for 277 s and +0.28 V for 56 s (vs. SCE), for 33 cycles in an 8 M aqueous solution of sodium nitrite at 80°C. Equivalent results can be achieved using a two-electrode cell with a voltage pulse of −4.1 V and +1.2 V for 277 and 56 s, respectively [20]. Figure 1(a) shows a schematic diagram of the three-electrode cell subjected to the EISA treatment. The saturated calomel electrode and graphite cylinder were used as the reference and counter electrodes, respectively.
Schematic diagram of an electrochemical test cell: (a) for the EISA treatment cell and (b) for the electrochemical corrosion test cell.
X-ray diffraction analysis
The phases of the EISA-treated and untreated samples were examined by X-ray diffraction (XRD) using Cu-Kα radiation (λ = 1.542 Å).
Electrochemical test
To evaluate the electrochemical corrosion behaviour according to the EISA treatment, a potentiodynamic polarisation test was employed for two different immersion times: 0 and 24 h. The different immersion times were used in the potentiodynamic polarisation test to examine the effects of the immersion time on the EISA-tested sample. The specimens were polarised dynamically from −0.3 to 1 V vs. open circuit potential (OCP) at a scan rate of 0.3 mV s−1.
EIS was used to determine the change in the electrochemical corrosion resistance. The EIS measurements were conducted at the OCP, applying a 10 mV amplitude sinusoidal voltage in 0.01-100 000 Hz frequency intervals. The impedance test was performed at different exposure times ranging from 3 to 96 h after the specimen was immersed in the electrolyte.
In addition, the Mott–Schottky measurement was conducted to evaluate the stability of the passive film on the steel surface. The tested specimens were polarised from −0.194 to 0.3003 V vs. OCP at a scan rate of 0.5 mV s−1. The potential range was applied in the passivity potential range of the anodic parts based on the potentiodynamic polarisation curves.
The reference and the counter electrodes for the electrochemical corrosion test were the saturated calomel electrode and platinum grid, respectively. A 0.1 N HCl solution was used as the electrolyte for all electrochemical tests. Figure 1(b) presents a schematic diagram of the electrochemical corrosion test cell.
All of the electrochemical tests were conducted in aerated and unstirred solutions at ambient temperature.
SIMS analysis
SIMS analysis using a Cs+ gun was used in the tested specimens before and after the EISA treatment, and after 24 h immersion in a 0.1 N HCl solution after the EISA treatment, to identify the presence of nitrogen on the steel surface. The detection area was 33 μm (ϕ) and the ions detected were carbon, nickel, nitrogen, chromium, iron and oxygen.
Results and discussion
Potentiodynamic polarisation measurement and SIMS analysis after EISA
Figure 2 presents the potentiodynamic polarisation test results before and after the EISA treatments, and Table 2 lists the corrosion parameters of the OCP, pitting potential (E p) and passivity current density (i pass). After the EISA treatment, the OCP and E p were increased, but the i pass was decreased, suggesting that the EISA treatment can contribute to the increase in resistance to pitting corrosion. This agrees well with the previous finding [22], showing that the deepest pit and the pit area of the EISA-treated specimen were shallower and smaller, respectively, than those of the untreated specimen. Actually, the appearance of multiple potentials of zero current during the anodic sweep was caused by the background oxygen reduction current. Nevertheless, it is also worth making a relative comparison of pitting potentials between the two specimens exposed to an acidic environment with oxygen. Anyway, the increase in resistance to the pitting corrosion of the EISA-treated specimen may be associated closely with the phase transition from α’-martensite to γ-austenite during the EISA treatment [2 -10]. In addition, the improvement of the pitting corrosion resistance after the EISA treatment may have resulted from a significant decrease in the amount of martensite phase, which was confirmed by XRD (Figure 3). On the other hand, the decrease in or elimination of the martensite phase does not always increase the corrosion resistance [23–28]. Chunchun et al. [23 -31] examined the effects of the martensite contents on the pitting and stress corrosion sensitivities and found that the sensitivities were not proportional to the martensite content. This suggests that the critical factor may not be the fraction of the martensite phase in the microstructure, but densification of the matrix caused by absorption of an element into the lattice [21]. Based on the XRD pattern (i.e. contraction of the γ-phase lattice parameter [21]), reported previously, the element was assumed to be nitrogen, which was reduced cathodically on the steel surface in a solution containing NaNO2 under the cathodic polarisation condition. In principle, the water reduction reaction could be a dominant cathodic reaction in a weakly alkaline solution under cathodic polarisation [32–37], and the H+ released can be reduced to atomic hydrogen, as shown in the following equations:
Potentiodynamic polarisation measurements of the EISA-treated and -untreated specimens. XRD test result of the EISA-treated and -untreated specimens. Potentiodynamic polarisation test results of the EISA-treated and -untreated specimens.
dissociated from NaNO2 in water (
) could be reduced cathodically, and finally, NO(ads) could be produced [38,39], as expressed by the following equation:


Considering the (electro) chemical processes, described above, it could be expected that several species of H, NO and/or N2 were produced and adsorbed on the surface. On the other hand, only H could be oxidised at the sub-surface under the anodic polarisation process in the EISA (Equation (4)). Therefore, H may not diffuse into the lattice, and the possible diffusing species were NO and/or N2, which may have resulted in the contraction of the γ-phase lattice parameter [21]. The proposed mechanism was supported in part by SIMS analysis, as shown in Figure 4. Because the high peak intensities at the outermost surface (approximately 200 nm) were due to the imperfect vacuum condition in the SIMS analysis equipment, the data can be neglected. The noticeable features in this analysis are that both nitrogen and oxygen peaks appeared at approximately 1.8-6.5 μm of the depth profile after the EISA treatment. In addition, the peaks from the two elements appeared at the same depth, suggesting that most diffusing species into the lattice were NO(ads), which was produced by Equation (3), and the diffusing depth was approximately 6.5 μm from the surface, which corresponds to the annealed depth reported by Burstein et al. [20]. Indeed, it is still unclear if the nitrogen existed as single NO or co-existed as NO and N2, and further attempts to clarify the existing form are needed. Nevertheless, it is worthy of note that the species that forms can lead to densification of the matrix, resulting in an increase in pitting corrosion resistance. The change in the characteristics of the passive film was analysed because the characteristics of the thin passive film formed on the outermost surface are one of the critical factors for the corrosion resistance of stainless steel, which will be discussed in the following section.
SIMS analysis of EISA (a) -untreated and (b) -treated specimens.
Mott–Schottky analysis
Figure 5 presents the Mott–Schottky plots of the specimens before and after the EISA treatments. Both plots showed positive slopes (i.e. characteristics of n-type semiconductor) within the range of passivity potential. On the other hand, they have different slopes, meaning that the density of donor sites, which are regarded simply as the defect density, in the passive film changed after the EISA treatment. The slope of the Mott–Schottky plots of the n-type semiconductor was calculated by the following equation [46,47]:
Mott–Schottky measurement of the EISA-treated and -untreated specimens.

Defect density of the EISA-treated and -untreated specimens.
Changes in corrosion behaviours of the EISA-treated specimen after pre-immersion
Figure 6 presents the potentiodynamic polarisation test results of the EISA-treated specimen which had been immersed in a 0.1 N HCl for 24 h. Although E p, which is known as a critical parameter for the localised corrosion resistance, was relatively unchanged, the OCP and i pass decreased and increased, respectively, suggesting that the passivity had degraded somewhat. The polarisation resistance (R p), which is inversely proportional to i corr, was also measured using an EIS test. As shown in Figure 7, the R p of the specimen without the EISA treatment increased progressively with increasing immersion time, from 0 to 96 h. On the other hand, the R p of the EISA-treated specimen tended to increase at an early stage of immersion, but it decreased significantly after 24 h immersion, and it was relatively constant with further immersion. This showed a similar trend with the polarisation behaviour: an increase in i pass of the EISA-treated specimen after 24 h immersion. These results were attributed to the decrease in thickness of the specimen by the corrosion process (i.e. Fe dissolution: Fe → Fe2+ + 2e−) with the immersion time. The strain-induced α′ phase at the outermost surface of the untreated specimen might have disappeared gradually by surface dissolution, showing a slight improvement in corrosion resistance at around the OCP with increasing immersion time. On the other hand, at the early stage of dissolution for the EISA-treated specimen, the desorption of NO and/or N2, which had absorbed on the surface, could make the specimen more resistive to corrosion by the formation of NH4 +, leading to an increase in local pH [48–53]. With further immersion at approximately 24 h, however, the specimen became much thinner and lots of NO and/or N2 species had dissolved, leaving only smaller portions remaining with an uneven distribution at the surface. This may weaken the corrosion resistance due to the formation of local galvanic cells between the NO- and/or N2-enriched and -depleted regions. To measure the dissolved thickness indirectly, the Wagner–Traud equation was used to fit the potentiodynamic polarisation curves; Table 4 lists kinetic parameters for corrosion. For the curve-fitting to the potentiodynamic polarisation data, the Wagner–Traud equation (Equation (6)) and Stern–Geary equation (Equation (7)) were employed.
Potentiodynamic polarisation measurements of the EISA-treated specimens before and after 24 h immersion in 0.1 M HCl solution. Nyquist plots, obtained by EIS, of (a) EISA-treated, (b) -untreated specimens and (c) polarisation resistance values of the tested specimens with immersion time. Various corrosion kinetic parameter values obtained by curve-fitting to potentiodynamic polarisation data.


The value of mpy, which was obtained by the following equation [54], for the EISA-treated samples at two different immersion times, 0 and 24 h, were 0.01375 and 0.83064, which are equal to 0.09569 and 5.78042 in μm/day, respectively.
The proposed mechanism described above was supported in part by SIMS analysis of the EISA-treated specimen, which had been conducted after 24 h immersion. As shown in Figure 8, some of the peaks from nitrogen and oxygen, which appeared at approximately 2.4-6.2 μm in the depth profile before immersion, disappeared due to Fe dissolution at the outer surface, and only one peak remained. Based on this analysis, the dissolution depth was approximately 4 μm, which agrees with the value of mpy to a certain degree.
Despite the several strengths of the EISA treatment, the significant reduction of α’ martensite and high hardness of the surface without heat treatment at several hundreds of degrees Celsius, the treatment has a technical limitation in that the surface characteristics, including the higher corrosion resistance, can only last for a limited period. Therefore, a significant increase in the electrochemical annealing depth in the short EISA treatment time can be one of the technical issues in this field, and further study on this issue will be required (Figure 8).
SIMS analysis of the EISA-treated specimen measured after 24 h immersion.
Conclusion
The changes in corrosion behaviour of the EISA-treated 304L stainless steel were evaluated using a range of electrochemical methods, and the results were supported in part by SIMS. The major findings on this study can be summarised as follows:
The EISA treatment composed of a series of anodic and cathodic electrochemical pulse increases the corrosion resistance in a 0.1 N HCl solution (i.e. increase in E p from potentiodynamic polarisation measurement and decrease in N D from the Mott–Schottky measurement). This may be associated closely with the surface densification effect caused by the absorption of NO and/or N2, which had been reduced cathodically during the EISA treatment. The improved corrosion resistance after the EISA treatment did not last long. In contrast to the early stages of immersion, with increasing immersion time exceeding 24 h, the R p of the EISA-treated specimen became smaller than that of the untreated specimen. This change in R p was closely related to the dissolution of NO and/or N2 in the outer surface, which was caused by the decrease in steel thickness via the corrosion process (i.e. Fe dissolution: Fe → Fe2+ + 2e−) with increasing immersion time. Therefore, despite the several strengths of the EISA treatment, it has a technical limitation in that the surface characteristics, including a higher corrosion resistance, can last only a limited time.
Disclosure statement
No potential conflict of interest was reported by the authors.
Footnotes
Data availability statement
The data supporting the findings of this study are available from the corresponding author upon reasonable request.
