Effect of calcium addition on the corrosion behavior of Mg–5Al alloy

The corrosion behavior of four Mg–5Al–xCa alloys (x = 0.0 to 2.0 wt.%) was evaluated in an alkaline NaCl solution. Surface analyses indicated that the benefits of Ca addition are the refinement of the precipitates and a decrease in grain size. Furthermore, the refinement of the precipitates (Mg₂Ca, Al₂Ca) became more complete with increasing of Ca content. The electrochemical tests revealed that the pitting resistance was improved in Ca-containing specimens. In addition, the polarization resistance of the Mg–5Al specimens increased with increasing Ca content. This is due to the fact that precipitation which is expected to act as a barrier is more continuous over the Mg matrix with a smaller grain size and higher precipitation density.     

Exfoliation and intergranular corrosion resistance of the 2198 Al–Cu–Li alloy with different thermomechanical treatments

In this study, the resistance to exfoliation and intergranular corrosion (IGC) of the 2198 Al–Cu–Li alloy submitted to different thermomechanical treatments (T3, T8, and T851) was investigated. The tests were carried out following the standard practices, ASTM G34-18 and ASTM G110-15, respectively. All the tested alloys showed susceptibility to exfoliation and some alloys showed susceptibility to IGC, but the artificially aged alloys presented a higher tendency to exfoliation. The extensive hydrogen evolution reaction (HER) was observed on the surfaces of artificially aged alloys when immersed in the EXCO solution. The HER resulted in an increase in solution pH with the time of immersion. Also, the weight losses related to the artificially aged alloys were higher than that of the naturally aged ones. The T8 treatment was the only condition that resulted in susceptibility to both, intergranular and transgranular corrosion, whereas the T851 treatment did not show IGC susceptibility, only transgranular corrosion. Finally, the 2198-T3 condition showed the highest corrosion resistance among the thermomechanical treatments tested. The results of the 2198 alloy subjected to various treatments were compared with that of the 2024-T3 alloy. This last alloy showed higher resistance to exfoliation and IGC as compared with the 2198 alloy.     

Comparison of the corrosion resistance of an Al–Cu alloy and an Al–Cu–Li alloy

ABSTRACT

In this study, the corrosion mechanisms of the AA2024-T3 and the AA2098-T351 were investigated and compared using various electrochemical techniques in 0.005?mol?L^?1 NaCl solution. The severe type of corrosion in the AA2098-T351 was intragranular attack (IGA) although trenching and pitting related to the constituent particles were seen. On the other hand, the AA2024-T3 exhibited severe localised corrosion associated with micrometric constituent particles, and its propagation was via grain boundaries leading to intergranular corrosion (IGC). Electrochemical techniques showed that the corrosion reaction in both alloys was controlled by diffusion. The non-uniform current distribution in both alloys showed that EIS was not a proper technique for comparing the corrosion resistance of the alloys. However, local electrochemical techniques were useful for the evaluation of the corrosion resistance of the alloys.     

Effect of erbium addition on the corrosion behaviour of Mg–Al alloys

The corrosion behaviour of two Mg–Al–Er alloys with increasing content of erbium (Mg₉₅Al₃Er₂ and Mg₉₅Al₂Er₃) has been evaluated in borate buffer solution and compared with that of the commercial AM60 alloy (Mg–6.0Al–0.13Mn, at%) employed in the automotive industry. Scanning electron microscopy and quantitative electron probe microanalysis were used to characterize the samples, prior and after the electrochemical tests. The experiments were carried out in 0.05 M H₃BO₃+0.075 M Na₂B₄O₇ solution with pH=8.4. Anodic polarization curves were recorded, potentiostatic current decay transients were obtained at anodic potentials and the polarization resistance was determined. The alloys show similar microstructures characterized by a Mg-based solid solution, surrounded by a very small amount of a secondary phase. The alloys investigated exhibit enhanced corrosion resistance with respect to AM60 alloy. Electrochemical investigations reveal that the surface layers formed on the erbium-containing alloys provide a better protective effectiveness than the magnesium hydroxide or aluminium hydroxide layer formed on AM60 in borate buffer solution. Based on preliminary analysis, the incorporation of erbium in the Mg(OH)₂ lattice is believed to be responsible for the improved corrosion behaviour of the Mg–Al–Er alloys.     

Microstructure,mechanical properties,and corrosion resistance of Mg–9Li–3Al–1.6Y alloy

Mg–9Li–3Al–1.6Y alloys were prepared through mixture method. The microstructure, mechanical properties, and corrosion resistance of the as-cast and asextruded alloys were studied by optical microscopy(OM),scanning electronic microscopy(SEM), X-ray diffraction(XRD), mechanical properties testing, and electrochemical measurement. The as-cast Mg–9Li–3Al–1.6Y alloy with the average grain size of 325 lm is composed of b-Li matrix, block a-Mg, and granule Al_2Y phases. After extrusion, the grain size of the as-cast alloy is obviously refined and reaches to 75 lm; the strength and elongation of the extruded alloy are enhanced by 17.20 % and49.45 %, respectively, owing to their fine microstructure and reduction of casting defects. The as-extruded alloy shows better corrosion resistance compared to the as-cast one, which may be related to the low stored energy and dislocation density in the extruded alloy, also the homogenization treatment before extrusion.     

Effect of mischmetal on the corrosion properties of Mg–5Al alloy

The effect of mischmetal (Mm) on the corrosion properties of Mg–5Al alloy was investigated by electrochemical techniques in 0.01 M NaCl solution as the alkaline condition (pH 12) and surface analyses. The electrochemical tests indicated that the pitting potential, time to pitting initiation, and charge transfer resistance of the Mg–5Al specimens increased with increasing Mm content. Surface analyses indicated that Mm promoted the formation of passive film in the absence of Mm products. In addition, the benefits of Mm addition are the refinement of the precipitates and reduction in grain size.     

Designing for the cerium-based conversion coating with excellent corrosion resistance on Mg–4Y–2Al magnesium alloy

The cerium salt chemical conversion baths containing KMnO₄ are applied to prepare protective coatings on the WA42 alloy surface, and the effect of the concentration of KMnO₄ on the microstructure and corrosion properties of the coatings is investigated by scanning electron microscopy, X-ray photoelectron spectroscopy, and electrochemical tests. The results indicate that with the addition of KMnO₄ to the conversion bath, the microstructure of the coating is more uniform and denser, and the coating with the KMnO₄ concentration of 4 g/L (4M coating) has the most uniform microstructure with the least microcracks. The 4M coating exhibits a two-layered structure, and it is mainly composed of MgO, Mg(OH)₂, CeO₂, Ce₂O₃, Ce(OH)₃, MnO, and MnO₂. In addition, as the KMnO₄ concentration increases from 0 to 6 g/L, the I_corr of the coatings in 3.5% NaCl solution decreases first and then increases, and the 4M coating shows the best corrosion resistance, which should attribute to the uniform and dense microstructure.     

Improvement of corrosion resistance of AZ91D magnesium alloy by gadolinium addition

Based on the previous investigation on beneficial introduction of holmium into magnesium alloy, the effect of gadolinium, an adjacent rare earth element, on corrosion resistance was examined. The corrosion behavior of two Mg-9Al-Gd alloys （Mg-9Al-0.45Gd and Mg-9Al-l.43Gd） was evaluated and compared with that of Mg-9Al alloy without Gd by means of specimen mass loss and hydrogen evolution in 3.5% NaCl solution saturated with Mg（OH）2. The Gd-containing alloys exhibit enhanced corrosion resistance with respect to the plain Mg-9Al alloy. The microstructures of Mg-9Al alloy and Mg-9Al-0.45 Gd alloy were observed by electron probe microanalysis （EPMA） and energy dispersion spectroscopy （EDS）. The alloys with Gd addition show a microstructure characterized by a phase solid solution, surrounded by minor amount of β phase and more grain-like Gd-containing phase. To illustrate the involved mechanism their polarization curves were recorded. The electrochemical investigations reveal that Gd addition shifts the corrosion potential of the alloy towards active, as Gd containing phase is more active and hence less cathodic. As a result, the micro-galvanic corrosion is suppressed. Moreover corrosion product films formed on the Gd containing alloys are more compact and provide a better protective effectiveness than that on the alloy without Gd against corrosion. Repassivation measurements in mixture solution of 0.21 mol/L K2CrO4＋0.6 mol/L NaCI also verify the beneficial role of Gd addition. Based on the present preliminary analysis, both the deposited Gd-containing phases and corrosion product films are believed to be responsible for the improved corrosion behaviour due to Gd addition.     

Influence of alloyed Nd content on the corrosion of an Al–5Mg alloy

The influence of neodymium (Nd) additions from 0 to 0.17 wt.% on the electrochemical response, corrosion, and hardness of a model 5xxx alloy (Al–5Mg) was studied. The combination of SEM, polarisation, constant immersion and nitric acid mass loss testing, followed by optical profilometry, revealed that Nd had no significant effect on pitting or general corrosion of Al–5Mg; however with Nd additions the extent of intergranular corrosion following sensitisation was decreased substantially. Nd additions also increased alloy hardness and thus microalloying with Nd was shown to improve the properties of Al–5Mg.     

Enhanced corrosion resistance of high strength Mg–3Al–1Zn alloy sheets with ultrafine grains in a phosphate-buffered saline solution

The corrosion behaviour of ultrafine grained AZ31Mg alloy sheets with very high strength, which were prepared by high-ratio differential speed rolling (HRDSR) technique, was studied in a phosphate-buffered saline solution. The corrosion resistance was greatly improved after HRDSR. This result was attributed to the enhanced stability of the Mg(OH)₂ layer due to the grain refinement and precipitation of various types of P-containing compounds on the stabilised Mg(OH)₂ layer. The HRDSR technique has a good potential to be used for the development of magnesium sheets with good combination of mechanical and biocorrosion properties.     

Effects of Al content on the corrosion properties of Mg–4Y–xAl alloys

The corrosion performances of Mg–4Y–xAl (x = 1, 2, 3, and 4 wt%) alloys in the 3.5% NaCl electrolyte solution are investigated by electrochemical tests, weight loss measurement and corrosion morphology observation. The results indicate that corrosion modes for the alloys are localized corrosion and the filiform type of attack. With Al concentration increasing from 1 to 4 wt%, the corrosion rate of Mg–4Y–xAl alloys decreases firstly and then increases, and WA42 alloy shows the best corrosion resistance. The addition of Al element to Mg–4Y alloys leads to the formation of Al₂Y and Al₁₁Y₃ intermetallic compounds and reduces the proportion of Mg₂₄Y₅ phase. Corrosion resistance of the Mg–4Y–xAl alloys mainly depends on the size and distribution of the second phases. Besides, the addition of excessive Al can greatly consumes the Y element in the matrix, thus leading to a less protective film on the alloys. The effect of the relative Volta potential changes between the second phases and α-Mg on corrosion resistance of Mg–4Y–xAl alloys is insignificant. The main corrosion products of the Mg–4Y–xAl alloys are Mg(OH)₂, Mg₃(OH)₅Cl·4H₂O, Mg_0.72Al_0.28(CO₃)_0.15(OH)_1.98(H₂O)_0.48, and Mg₄Al₂(OH)₁₂CO₃·3H₂O.     

Effect of flame rectification on corrosion property of Al–Zn–Mg alloy

The corrosion resistance of Al–Zn–Mg alloy subjected to different times in flame rectification was investigated based on the exfoliation corrosion test. The results indicate that the flame rectification deteriorates the exfoliation corrosion resistance of Al–Zn–Mg alloy. The corrosion resistance of Al–Zn–Mg alloy is ranked in the following order: base metal>two times>three times>one time of flame rectification. The exfoliation corrosion behavior was discussed based on the transformation of precipitates at grain boundaries and matrix. With increasing the number of times in flame rectification, the precipitate-free zones disappeared and the precipitates experienced dissolution and re-precipitation. The sample was seriously corroded after one time of flame rectification, because the precipitates at grain boundaries are more continuous than those in other samples.     

Effect of microstructural features on the corrosion behavior of severely deformed Al–Mg–Si alloy

The aim of this study was to determine the influence of severe plastic deformation processing and the changes in microstructure resulting therefrom on the corrosion resistance of an Al–Mg–Si alloy. The alloy was processed using incremental equal channel angular pressing, which caused a reduction in grain size from 15 to 0.9 µm. The grain refinement was accompanied by an increase in the number of grain boundaries and dislocations, and by changes in grain orientation. However, there was no change in the size and number of intermetallic particles, which presumably resulted in a constant number of galvanic couplings. Electrochemical experiments revealed only slight differences between the samples before and after processing. Higher potential transients/oscillations upon immersion and increased corrosion currents in the vicinity of corrosion potential point to slightly higher reactivity of the most refined material. This indicates that intermetallic particles are the most crucial microstructural elements in terms of corrosion resistance. Their impact exceeds that of grain boundaries, in particular, at the stage of corrosion initiation. The development of corrosion attack is controlled more by the microstructure of the matrix as the grain refinement resulted in a less pronounced corrosion attack in comparison with the coarse-grained sample.     

Effect of Mg addition on the creep and yield behavior of an Al–Sc alloy

The relationships between microstructure and strength were studied at room temperature and 300 °C in an Al–2 wt% Mg–0.2 wt% Sc alloy, containing Mg in solid-solution and Al₃Sc (L1₂ structure) as nanosize precipitates. At room temperature, the yield strength is controlled by the superposition of solid-solution and precipitation strengthening. At 300 °C and at large applied stresses, the creep strength, which is characterized by a stress exponent of ~5, is significantly improved compared to binary Al–Sc alloys, and is independent of the size of the Al₃Sc precipitates. At small applied stress, a threshold stress exists, increasing from 9% to 70% of the Orowan stress with increasing Al₃Sc precipitate radius from 2 to 25 nm. An existing model based on a climb-controlled bypass mechanism is in semi-quantitative agreement with the precipitate radius dependence of the threshold stress. The model is, however, only valid for coherent precipitates, and the Al₃Sc precipitates lose coherency for radii larger than 11 nm. For semi-coherent precipitates with radii greater than 15 nm, the threshold stress remains high, most likely because of the presence of interfacial misfit dislocations.     

Enhanced corrosion resistance of micro-arc oxidation coated magnesium alloy by superhydrophobic Mg−Al layered double hydroxide coating

To further enhance the corrosion resistance of the porous micro-arc oxidation (MAO) ceramic layers on AZ31 magnesium alloy, superhydrophobic Mg−Al layered double hydroxide (LDH) coating was fabricated on MAO-coated AZ31 alloy by using in-situ growth method followed by surface modification with stearic acid. The characteristics of different coatings were investigated by XRD, SEM and EDS. The effect of the hydrothermal treatment time on the formation of the LDH coatings was studied. The results demonstrated that the micro-pores and cracks of MAO coating were gradually sealed via in-situ growing LDH with prolonging hydrothermal treating time. Electrochemical measurement displayed that the lowest corrosion current density, the most positive corrosion potential and the highest impedance modulus were observed for superhydrophobic LDH/MAO coating compared with those of MAO coating and LDH/MAO coating. Immersion experiment proved that the superhydrophobic LDH/MAO coating with the active anti-corrosion capability significantly enhanced the long-term corrosion protection for MAO coated alloy.     

On the origin of the high coarsening resistance of Ω plates in Al–Cu–Mg–Ag Alloys

The thickening kinetics of Ω plates in an Al–4Cu–0.3Mg–0.2Ag (wt. %) alloy have been measured at 200, 250 and 300°C using conventional transmission electron microscopy techniques. At all temperatures examined the thickening showed a linear dependence on time. At 200°C the plates remained less than 6 nm in thickness after 1000 h exposure. At temperatures above 200°C the thickening kinetics are greatly increased. Atomic resolution Z-contrast microscopy has been used to examine the structure and chemistry of the (001)_Ω6(111)_α interphase boundary in samples treated at each temperature. In all cases, two atomic layers of Ag and Mg segregation were found at the broad face of the plate. The risers of the thickening ledges and the ends of the plates were free of Ag segregation. The necessary redistribution of Ag and Mg accompanying a migrating thickening ledge occurs at all temperatures and is not considered to play a decisive role in the excellent coarsening resistance exhibited by the Ω plates at temperatures up to 200°C. Plates transformed at 200°C rarely contained ledges and usually exhibited a strong vacancy misfit normal to the plate. A large increase in ledge density was observed on plates transformed at 300°C, concomitant with accelerated plate thickening kinetics. The high resistance to plate coarsening exhibited by Ω plates at temperatures up to 200°C, is due to a prohibitively high barrier to ledge nucleation in the strong vacancy field normal to the broad face of the plate. Results also suggest that accommodation of the large misfit that exists normal to the broad face of the plate is unlikely to provide the driving force for Ag and Mg segregation.     

Dynamic recrystallization,texture and mechanical properties of high Mg content Al–Mg alloy deformed by high strain rate rolling

The Al–Mg alloy with high Mg addition (Al–9.2Mg–0.8Mn–0.2Zr-0.15Ti, in wt.%) was subjected to different passes (1, 2 and 4) of high strain rate rolling (HSRR), with the total thickness reduction of 72%, the rolling temperature of 400 °C and strain rate of 8.6 s⁻¹. The microstructure evolution was studied by optical microscope (OM), scanning electron microscope (SEM), electron backscattered diffraction (EBSD) and transmission electron microscope (TEM). The alloy that undergoes 2 passes of HSRR exhibits an obvious bimodal grain structure, in which the average grain sizes of the fine dynamic recrystallization (DRX) grains and the coarse non-DRX regions are 6.4 and 47.7 μm, respectively. The high strength ((507±9) MPa) and the large ductility ((24.9±1.3)%) are obtained in the alloy containing the bimodal grain distribution. The discontinuous dynamic recrystallization (DDRX) mechanism is the prominent grain refinement mechanism in the alloy subjected to 2 passes of HSRR.     

Novel multilayer Mg–Al intermetallic coating for corrosion protection of magnesium alloy by molten salts treatment

A novel multilayer Mg–Al intermetallic coating on the magnesium alloy was obtained by AlCl₃–NaCl molten salt bath treatment. The molten salt was treated at 400 °C, which is lower than the treatment temperature of solid diffusion Al powder. The thick Al₁₂Mg₁₇, Al_0.58Mg_0.42 and Al₃Mg₂ multilayer Mg–Al intermetallic coating forms on the magnesium alloy. The corrosion resistance of AZ91D alloy with and without coating by multilayer of Mg-Al intermetallic compound was evaluated by electrochemical impedance spectroscopy measurements in 3.5% (mass fraction) NaCl solution. The polarization resistance value of the multilayer coating on the magnesium alloy by molten salt bath treatment is greater than that of the uncoated one, which is attributed to the homogenously distributed intermetallic phases.     

Effect of Y addition on microstructure and mechanical properties of Mg–Zn–Mn alloy

The effects of Y on the microstructure and mechanical properties of Mg–6Zn–1Mn alloy were investigated. The results show that the addition of Y has significant effect on the phase composition, microstructure and mechanical properties of Mg–6Zn–1Mn alloy. Varied phases compositions, including Mg₇Zn₃, I-phase (Mg₃YZn₆), W-phase (Mg₃Y₂Zn₃) and X-phase (Mg₁₂YZn), are obtained by adjusting the Zn to Y mass ratio. Mn element exists as the fine Mn particles, which are well distributed in the alloy. Thermal analysis and microstructure observation reveal that the phase stability follows the trend of X>W>I>Mg₇Zn₃. In addition, Y can improve the mechanical properties of Mg–Zn–Mn alloy significantly, and the alloy with Y content of 6.09% has the best mechanical properties. The high strength is mainly due to the strengthening by the grain size refinement, dispersion strengthening by fine Mn particles, and introduction of the Mg–Zn–Y ternary phases.