• Sn addition promotes rapid stabilization of rust layers on weathering steel in marine environments, reducing the time needed for protective rust formation.
• A synergistic effect between Sn and Cr accelerates densification of the rust layer, enhancing its resistance to chloride ion penetration.
• The study provides an environmentally friendly alternative to chemical stabilization treatments, mitigating pollution concerns.
• Findings support the use of Sn as an effective alloying element for improving corrosion resistance of weathering steel in coastal applications.
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