Development and Experimental Assessment of a Controlled Corrosion Testing Apparatus for Mild Steel and ABS Steel

A laboratory-scale corrosion testing apparatus was developed to replicate the hot, salty, and humid conditions present in tropical marine habitats. Both mild steel and ABS steel specimens were electrolyzed and exposed to controlled temperatures of 25, 28, and 40 degrees Celsius. Surface deterioration was characterized using scanning electron microscopy (SEM), and corrosion rates were calculated using corrosion penetration rate (CPR) calculations. The findings showed that mild steel was more prone to corrosion (515 MPY at 40°C) than ABS steel (404 MPY), and that corrosion was increased by 6–8 times by electrolysis. Elevated temperatures exacerbated corrosion and were linked to microstructural features such as pitting, rust layer thickness, and magnetite production. SEM micrographs confirmed localized attack and uneven oxide deposition. These findings show that temperature and electrochemical activity are the main factors causing corrosion in tropical areas. Selecting corrosion-resistant alloys and developing protective coating plans for industrial and marine applications are made simpler by the recommended configuration's reproducible and reasonably priced platform for evaluating material performance. The study innovatively addresses a major research gap and offers a cost-effective and innovative alternative to conventional test chambers by developing a low-cost, region-specific corrosion testing equipment that replicates Bangladesh's tropical saline conditions.