Influence of Reduction Ratio on Residual Stress and Corrosion Behavior of AISI 1006 Steel in Chloride Solutions

AISI 1006 steel, widely used in automotive, construction, and manufacturing industries, exhibits excellent mechanical properties but remains susceptible to corrosion in chloride-rich environments. The reduction ratio in metal forming significantly alters the material's residual stress distribution and surface properties, both of which influence its corrosion behavior. This study investigates the effect of reduction ratio on the residual stress and corrosion resistance of AISI 1006 steel in 1M and 2M NaCl solutions. Electrochemical techniques, including Open Circuit Potential (OCP), Electrochemical Impedance Spectroscopy (EIS), and Potentiodynamic Polarization (PD), were employed to assess corrosion resistance. Additionally, surface characterization via X-Ray Diffraction (XRD), Atomic Force Microscopy (AFM), and salt spray testing provided insights into residual stress development and atmospheric degradation. The findings reveal a strong correlation between reduction ratio, residual stress, and electrochemical properties, affecting charge transfer resistance, corrosion current density, and surface morphology. Understanding these relationships is critical for optimizing metal forming processes to enhance corrosion resistance and extend the service life of AISI 1006 steel in aggressive environments.