The microstructure and corrosion behavior of pure magnesium, with 25 ppm Fe but a high corrosion rate, have been studied in this work. It was found that Fe-rich particles, containing also Si, distribute non-uniformly in the Mg matrix and they are spaced at a distance of 100-1000 μm. Before the initiation of localized corrosion, Fe-rich particles play a key role in determining the overall corrosion behavior by supporting hydrogen evolution. During corrosion propagation, Fe-rich particles could be oxidized once they were detached from the Mg matrix and, consequently, lose their cathodic activation. Once the corrosion has taken place over majority of the surface, the effects of crystallographic orientation of the underlying metal dominate the last stage of corrosion, which propagates parallel to the (0001) Magnesium alloys are of great value for industrial applications due to their low density and high strength-to-weight ratio. However, a major deficiency is their comparatively poor corrosion resistance when exposed to aqueous and humid environments.1,2 Consequently, there is a demand to develop magnesium alloys with improved corrosion resistance.
2,3The equilibrium potential for magnesium oxidation is well below the equilibrium potential for hydrogen evolution over the entire pH range of practical interest. As a consequence, the cathodic reaction of hydrogen evolution largely dominates over oxygen reduction during corrosion in an aqueous environment. For this reason, the presence of elements with low overpotentials (or high exchange current density) for hydrogen evolution is likely to produce detrimental effects on the corrosion resistance due to increase in the hydrogen evolution rate. Hanawalt et al. 4 found that four elements (Fe, Ni, Cu, and Co) had a very profound effect on accelerating the corrosion rate of Mg in chloride-containing aqueous environments even at concentrations below 0.2 wt%. Subsequent studies have confirmed that the most critical factor affecting the corrosion behavior of Mg is the presence of impurities.3