Assessment of Corrosion in Naval Steels Submerged in Artificial Seawater Utilizing a Magnetic Non-Destructive Sensor

This work presents a comprehensive evaluation of corrosion progression in DH36 naval steel through the integration of electrochemical impedance spectroscopy (EIS), weight loss, scanning electron microscopy (SEM), and advanced magnetic non-destructive techniques under artificial seawater (ASW, ASTM D1141) and natural marine conditions. Quantitative correlations are established between corrosion layer growth, electrochemical parameters, and magnetic permeability, demonstrating the magnetic sensor’s capacity for the real-time, non-invasive assessment of marine steel degradation. Laboratory exposures reveal a rapid initial corrosion phase with the formation of lepidocrocite and goethite, followed by the densification of the corrosion product layer and a pronounced decline in corrosion rate, ultimately governed by diffusion-controlled kinetics. Notably, changes in magnetic permeability closely track both the thickening of non-magnetic corrosion products and microstructural deterioration, with declining μmax and increased hysteresis widths (FWHM) sensitively indicating evolving surface conditions. A direct comparison with in situ marine immersion at Rafina confirms that the evolution of corrosion morphology and the corresponding magnetic response are further modulated by biofilm development, which exacerbates the attenuation of measured surface permeability and introduces greater variability linked to biological activity. These findings underscore the robustness and diagnostic potential of magnetic non-destructive sensors for the predictive, condition-based monitoring of naval steels, bridging laboratory-controlled observations and complex real-world environments with high quantitative fidelity to corrosion kinetics, phase evolution, and microstructural transformations, thus guiding the strategic deployment of protection and maintenance regimens for naval fleet integrity.