The chemical reactivity of oxide-free weld joints made of thermo-hardened carbon steel in different electrolytes was investigated by chronopotentiometry, electrochemical impedance spectroscopy (EIS) and scanning electron microscopy (SEM). The objective was to identify the role of different electrolyte constituents on the electrochemical behaviour of the different materials constituting the weld joint, namely the weld material, the heat affected zone (HAZ) and the base carbon steel. Hardness measurements by Vickers and nano-indentation techniques indicated that the weld material is harder than the heat affected zone and the base carbon steel due to a Widmanstatten ferrite-type structure of the weld. Electrochemical measurements were performed on polished cross-sections on these weld joints in four electrolytes containing different additives. The weld joints are active in all tested electrolytes and the composition of the electrolytes dictates the dissolution even though the main chemical reactivity mechanism remains unaffected. A balanced presence of oxidative agent, inhibitor and HF in the electrolyte is necessary to obtain a homogeneous chemical attack on weld joint and Si-rich inclusion removal in weld material, while avoiding excessive attack roughening and/or pitting of the carbon steel. (C) 2007 Elsevier Ltd. All rights reserved.