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Purpose -The purpose of this paper is to explore the long-term corrosion behavior of carbon steel in 3% NaCl solution and evaluate the effect of rust layer on the corrosion process. Design/methodology/approach -The corrosion behavior of rusted carbon steel in 3% NaCl solution was studied by means of infrared spectroscopy (IR) and electrochemical impedance spectroscopy (EIS). Findings -The results indicated that the corrosion of carbon steel was affected by chloride ion in initial immersion and then controlled by the rust layer. The rust layer consisted of a thin outer layer (g-FeOOH layer) and a thick inner layer (Fe 3 O 4 layer). The outer rust layer facilitated the cathodic process via reduction of g-FeOOH, while the inner rust layer provided a large cathode area and oxygen could be reduced on its surface. As a result, the corrosion rate of carbon steel was determined by the limiting diffusion rate of oxygen and stabilized at a high value. Originality/value -The corrosion model of rusted carbon steel in 3% NaCl solution was established. It is probable that the iron rust in all slightly acidic water with low alkalinity can promote the corrosion process via reduction of g-FeOOH. Anti-corrosion measures for iron in this type of solutions should be aimed to reduce the promoting effect of rust layer on the metal corrosion. The NaCl solution prepared from tap water is more suitable for the substitution of artificial water than that prepared from deionized water.

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