Surface Characterization of Hot-Rolled AISI 440C Round Wire at the Different Steps of the Typical Production Process

This study investigates the surface characteristics and corrosion behavior of a high-C martensitic stainless steel (AISI 440C) at different stages of its manufacturing process. As a class, these steels prioritize high mechanical properties and wear resistance over superior corrosion resistance. Hot working operations, such as rolling, create a surface oxide scale that must be removed via pickling to restore the material’s inherent corrosion resistance. This process also eliminates the underlying Cr-depleted layer, allowing for the re-establishment of a protective passive film. Using potentiodynamic polarization curves and micrographic analysis, the material’s behavior in different conditions, as-rolled, with a post-heat treatment oxide scale, and in a bare, oxide-free state, has been assessed. The results showed that the material lacks stable passive behavior under all conditions. The as-rolled and heat-treated conditions both exhibited active behavior and formed thick, nonadherent corrosion products. The oxide layer formed after heat treatment performed the worst, showing a significant increase in corrosion current density. These findings confirm the material’s susceptibility to corrosion in Cl− ion-rich environments, highlighting the need for limited storage in such conditions and rapid pickling after thermal processing to mitigate surface damage.