Root cause of corrosion failure of tin coating on wire clamp in marine atmosphere

The failure cause of a tinned copper wire clamp in marine atmosphere was studied systematically by X-ray photoelectron spectroscopy, scanning electron microscopy with energy dispersive spectroscopy and electrochemical measurements. The main components of the green rust on the surface of the damaged wire clamp are SnO2, CuO, Cu2Cl(OH)3 and CuCO3(OH)2. Much of green rust distributes at the platform edge along the axial direction on the crimp connection, and severe corrosion and corrosion pits occur at the platform edge zone along the axial direction. The enriching Cl- at the marine atmosphere and the existing O2 in air collectively enhance the corrosion process of the tin coating and the copper matrix. Finite element model results show that the residual stress and strain of the tin coating are the largest at the platform edge along the axial direction on the crimp connection, and the corresponding electrode potential of the tin coating at this zone drops significantly. The above results indicate that the residual strain increases the driving force of the corrosion electrochemical reactions and accelerates the corrosion rate and the pit corrosion of the tin coating at this zone.

Automated summary

The failure of a tinned copper wire clamp in a marine atmosphere was systematically studied, revealing that the presence of green rust and residual strain led to accelerated corrosion.