Corrosion behaviour of friction-bit-joined and weld-bonded AA7075-T6/galvannealed DP980

Joining of aluminium alloys 7075-T6 and galvannealed dual phase 980 steel was achieved by friction bit joining (FBJ) and weld-bonding (FBJ?+?adhesive) processes. Accelerated laboratory-scale corrosion tests were performed on both FBJ only and weld-bonded specimens to study joint strength under a corrosive environment. Static lap shear tests showed that both FBJ only and weld-bonded cases generally retained more than 80% of the joint strength of non-corroded specimens at the end of corrosion testing. The presence of Zn/Fe coating on the steel substrate resulted in improved corrosion resistance for FBJ specimens, compared to joints produced with bare steel. An optical microscopy was used for cross-sectional analysis of corroded specimens. Some corrosion on the joining bit was observed near the bit head. However, the joining bit was still intact on the steel substrate, indicating that the primary bond was sound.     

Cold spray deposition of a WC-25Co cermet onto Al7075-T6 and carbon steel substrates

This work focussed on the deposition of wear-resistant and corrosion-resistant WC-25Co cermet powders on carbon steel and aluminium (Al7075-T6) substrates by cold gas spraying (CGS). The unique combination of mechanical, physical and chemical properties of WC-Co cermets has led to their widespread use for the manufacture of wear-resistant parts. X-ray diffraction tests were run on the powder and coatings to determine possible phase changes during the spraying process. The bonding strength of the coatings was measured by adhesion tests (ASTM C633-08). The sliding (ASTM G99-04) and abrasive (ASTM G65-00) wear resistance of the coatings were also studied. Corrosion resistance was determined by electrochemical measurements and salt fog spray tests (ASTM B117-03). CGS achieved thick, dense and hard WC-25Co coatings on both aluminium alloy Al7075-T6 and carbon steel substrates, with excellent tribological and electrochemical properties. We thus conclude that this method is very competitive compared with conventional thermal spraying techniques, giving thick, dense and hard coatings on both aluminium alloy Al7075-T6 and carbon steel substrates, with excellent tribological and electrochemical properties.     

Salt fog corrosion behavior of high-velocity oxygen-fuel thermal spray coatings compared to electrodeposited hard chromium

The corrosion behavior of several coating/substrate combinations was determined using the ASTM B117 Salt Fog Test. The coatings were electrodeposited hard chromium (EHC) and two high-velocity oxygen-fuel (HVOF) thermal-sprayed coatings, tungsten-carbide/cobalt (WC/Co) and Tribaloy 400 (T400). The substrates were 4340 steel, 7075 aluminum alloy, and PH13-8 stainless steel. On the 7075 Al alloy, a sulfamate nickel layer was deposited prior to the deposition of hard chromium. The results indicated that on the 4340 steel none of the coatings provided significant protection, with equivalent performance between the EHC and WC/Co coatings and slightly poorer performance for the T400. On the 7075 Al alloy, the EHC with sulfamate nickel exhibited excellent performance as no pits or blisters were noted on the faces or edges of the samples. The WC/Co showed no pitting or blistering on the faces but had a significant amount of pitting along the edges. The EHC and WC/Co coatings performed well on the 13-8 stainless steel as no pits or blisters were noted on the faces or edges. The T400 coatings had rust stains on the faces and edges but defects could not be seen with the unaided eye or at a 7× magnification.     

Evaluation of WC–17Co and WC–10Co–4Cr thermal spray coatings by HVOF on the fatigue and corrosion strength of AISI 4340 steel

It is known that chromium electroplating is related to the reduction in the fatigue strength of base metal. However, chromium results in protection against wear and corrosion combined with chemical resistance and good lubricity. Environmental requirements are an important point to be considered in the search for possible alternatives to hard chrome plating. Aircraft landing gear manufactures are considering WC thermal spray coating applied by the high-velocity oxygen-fuel (HVOF) process an alternative candidate, which shows performance at least comparable to results, obtained for hard chrome plating. The aim of this study is to compare the influence of WC–17Co and WC–10Co–4Cr coatings applied by HVOF process and hard chromium electroplating on the fatigue strength of AISI 4340 steel, with and without shot peening. S–N curves were obtained in axial fatigue test for base material, chromium plated and tungsten carbide coated specimens. Tungsten carbide thermal spray coating results in higher fatigue strength when compared to hard chromium electroplated. Shot peening prior to thermal spraying showed to be an excellent alternative to increase fatigue strength of AISI 4340 steel. Experimental data showed higher axial fatigue and corrosion resistance in salt fog exposure for samples WC–10Co–4Cr HVOF coated when compared with WC–17Co. Fracture surface analysis by scanning electron microscopy (SEM) indicated the existence of a uniform coverage of nearly all substrates.     

Effects of electroplated zinc-nickel alloy coatings on the fatigue strength of AISI 4340 high-strength steel

Recovered substrates have been extensively used in the aerospace field. Cadmium electroplating has been widely applied to promote protective coatings in aeronautical components, resulting in excellent corrosion protection combined with a good performance in cyclic loading. Ecological considerations allied to the increasing demands for corrosion resistance have resulted in the search for possible alternatives. Zinc-nickel (Zn-Ni) alloys have received considerable interest recently, because these coatings show advantages such as a good resistance to white and red rust, high plating rates, and acceptance in the market. In this study, the effect of electroplated Zn-Ni coatings on AISI 4340 high-strength steel was analyzed for rotating bending fatigue strength, corrosion, and adhesion resistance. The compressive residual stress field was measured by x-ray diffraction prior to fatigue tests. Optical microscopy documented coating thickness, adhesion characteristics, and coverage extent for nearly all substrates. Fractured fatigue specimens were investigated using scanning electron microscopy (SEM). Three different Zn-Ni coating thicknesses were tested, and comparisons with the rotating bending fatigue data from electroplated Cd specimens were performed. Experimental results differentiated the effects of the various coatings on the AISI 4340 steel behavior when submitted to fatigue testing and the influence of coating thickness on the fatigue strength.     

Galvanic corrosion of aluminium alloy members of bridge guiderails under severe atmospheric exposure conditions

ABSTRACT

Aluminium alloys are nowadays preferred as materials for bridge guiderails especially for bridges connecting oceanic islands or spanning inlets due to their inherent corrosion resistance. But because of the limited mechanical strength of aluminium alloy, fasteners of guiderail members are made from steel materials. It has been found that contact between bare steel fasteners and aluminium alloy members can cause galvanic corrosion in the aluminium alloy. Research was carried out to investigate the capability of different surface treatments on fasteners and aluminium alloy members to inhibit galvanic corrosion under atmospheric exposure for periods of one and three years. It was found, among other results, that stainless steel fasteners treated with zinc flake coating were the most effective inhibitors of galvanic corrosion on aluminium alloy members.     

Effect of anodic oxidation on fatigue performance of 7075-T6 alloy

Effect of anodic oxidation on fatigue performance of 7075-T6 alloy for pre-corroded and non-corroded specimens has been investigated by conducting a series of rotary bending fatigue tests at 95 Hz. The anodized specimens with different coating thickness (6, 12 and 23 μm) were exposed to 3.5 wt.% NaCl solution for 6, 48, 96 and 240 h. The results indicate that oxidation has a tendency to decrease the fatigue performance. Fatigue strength was reduced with increasing coating thickness; approximately 40% reduction for a 23 μm thick coating was obtained. It was observed that oxidation mitigated pitting corrosion. Superior corrosion resistance was obtained for the thickest coating layer. Fatigue tests with pre-corroded specimens showed that fatigue life of coated specimens was significantly affected by pre-corrosion, except for the specimen with the thickest coating layer. When the pre-corroded bare and coated specimens were compared, the coating improved the fatigue performance in high cycle fatigue (> 10⁵) only and it degraded the fatigue performance in low cycle regime.     

Influence of pre-treatments in cerium conversion treatment of AA2024-T3 and 7075-T6 alloys

The role of pre-treatment in the formation of a cerium conversion coating is investigated for the protection of AA2024-T3 and 7075-T6 alloys. The alloys were alkaline-etched and de-smutted in nitric acid, prior to cerium treatment in Ce(NO₃)₃ at 85 °C with H₂O₂ accelerator. Potentiodynamic polarization studies in 3.5% NaCl solution revealed a large shift of  300 mV of the corrosion potential below the pitting potential for the 7075-T6 alloy, which correlated with the development of a finely-textured, uniform coating. However, the formation of a uniform coating and protection was dependent upon the time of de-smutting, with non-uniform coatings resulting from extended times of de-smutting. In contrast, non-uniform coatings developed on the 2024-T3 alloy, with pitting potential at the corrosion potential, irrespective of the time of de-smutting. Findings for the 2024-T3 alloy indicate that extended de-smutting affects the enrichment of alloying elements.     

Hydrogen permeation behavior of nickel electroplated AISI 4340 steel

The role of the electroplated nickel layer on hydrogen permeation through AISI 4340 steel was investigated by a electrochemical hydrogen permeation test. The permeation test, composed of three steps, was conducted to measure the hydrogen diffusivity and surface hydrogen concentration. A constant current of 20 mAcm^-2 and a constant potential of -100 mV vs. Ag/AgCl electrode were applied to the hydrogen entry and exit cells, respectively. The thickness of the electroplated nickel layer on AISI 4340 steel increased in a linear fashion with an increase in electroplating time. The nickel coated layer contributed to a decrease in the hydrogen permeability of nickel coated AISI 4340 steel specimens. This is due to the fact that the surface hydrogen concentration and hydrogen diffusivity in nickel coated layer were lower than those of AISI 4340 steel substrate. Especially, low hydrogen diffusivity decreased significantly with hydrogen permeability. The critical effective hydrogen diffusivity for barrier of nickel electroplated AISI 4340 steel specimens was higher than the hydrogen diffusivity of AISI 4340 steel specimen. It is proposed then that the thin nickel layer on AISI 4340 steel acts as a barrier for hydrogen permeation through AISI 4340 steel.     

Microstructure and corrosion resistance of molybdenum and aluminum coatings thermally sprayed on 7075-T6 aluminum alloy

Pitting corrosion upon 7075-T6 high strength aluminum alloy, often associated with cathodic intermetallic particles decreases its fatigue life by a factor of about 6 to 8. In order to improve the corrosion resistance of this alloy, arc spray coatings of molybdenum and aluminum are applied. The open circuit potential and potentiodynamic polarization measurements made in 3.5% NaCl naturally aerated solution reveal that the molybdenum coating, which has an excellent hardness, shifts the 7075-T6 corrosion potential (E _corr) to noble values and increases slightly the corrosion current density (i _corr). On the contrary, when the aluminum coating alloy is applied, both E _corr and i _corr are shifted to better values. The increase of i _corr of the alloy when molybdenum coating is applied can be attributed to the high porosity present into the coating. On the other hand, microstructure observations of the aluminum coating reveal a small porosity, which helps the formation of passive oxide film that protects the coating against a further corrosion.     

Corrosion protection of pure aluminium and aluminium alloy (AA7075) in salt solution with silane‐based sol–gel coatings

Sol–gel films of tetraethoxysilane (TEOS), phenyltriethoxysilane (PTES) and phenyltrimethoxysilane (PTMS) were prepared on aluminium and aluminium alloy AA7075 and characterised. The corrosion inhibition properties of uncoated and coated specimens were evaluated with potentiodynamic polarisation scan, linear polarisation resistance and open circuit potential measurements. With scanning electron microscopy and optical microscopy effects of the sol–gel coating were shown. Weight loss measurements were performed at different pH‐values. More hydrophobic coatings as PTMS show a considerably better corrosion inhibition capacity as compared to the capacity provided by less hydrophobic ones as TEOS and PTES.     

Einfluß von Beschichtungen auf das Schwingungsrißkorrosionsverhalten des Chromstahls X20Cr13

Influence of coatings on the corrosion fatigue behaviour of 13% chromium steel The influence of coatings on the corrosion fatigue behaviour of 13% chromium steel has been studied. There have been selected different coating systems: Barrier coating (enamel), diffusion coatings, (aluminizing, chromizing) and anodic coating, (aluminium, zinc, tin, cadmium). The corrosion fatigue limits of coated with uncoated specimens in neutral NaCl-solution are compared. Salt-concentrations were 0,01 and 22% (? 0,38 M) NaCl at 80°C and 150°C. The tests were carried out with alternating tensions and a constant frequency of 50 Hz. Only the use of andic coatings improved the corrosion fatigue behaviour of the chromium steel.     

Nondestructive analysis of pitting corrosion characteristics on EN AW-2024-T3 using 3D optical pattern profilometry

High-strength age-hardenable aluminium alloys are susceptible to localised corrosion. It is vital to monitor the evolution of the corrosion depth in order to prevent a critical degradation of the mechanical properties. This study presents the application of 3D optical pattern profilometry for the analysis of the pitting corrosion behaviour of the aluminium alloy EN AW-2024-T3. Therefore, measurements were conducted using a 1?M NaCl solution at different exposure times. The measurements are compared to the results of optical microscopy investigations of metallographic specimens as well as laser scanning microscopy measurements. In immersion bath tests, the 3D pattern profilometry shows a high measurement accuracy of the pitting corrosion. Regarding the pit characteristics, corroded metal sheets exhibit an increase in the pit depth, volume and area with an increasing exposure time of up to 312?h and then decrease. Moreover, a higher increase in the width in rolling direction than perpendicular to it is noticeable.     

Corrosion of aluminium alloy A6061-T6 members embedded in alkaline materials

Owing to the corrosive conditions in coastal areas, aluminium alloy railings and similar structures are normally used on infrastructure works such as bridges and roads located in such areas because aluminium alloys are inherently corrosion resistant. However, to achieve rigid support, aluminium alloy members are often embedded in concrete. Consequently, the embedded parts undergo corrosion caused by the alkaline content of the cement used in the concrete. This research was carried out to study the corrosion behaviour on both the embedded and unembedded sides of aluminium alloy A6061-T6 members embedded in the concrete and also to investigate the ability of a combined coating of anodic oxide and organic film to inhibit corrosion. Additionally, the influence of scratch damage on the performance of this coating material was evaluated.     

Pit-to-crack transition in pre-corroded 7075-T6 aluminum alloy under cyclic loading

Pit-to-crack transition experiments were conducted on 1.600 mm and 4.064 mm 7075-T6 aluminum alloy. Specimens were corroded using a 15:1 ratio of 3.5% NaCl solution and H₂O₂ prior to fatigue loading. Cracks originating from corrosion pits were visually investigated in order to understand how pit-to-crack transitions occur.All prior corroded specimens in the study fractured from cracks associated with pitting. Pit-to-crack transition was successfully acquired visually. Corroded 7075-T6-4.064 mm specimens experienced more of an overall fatigue life reduction than 7075-T6-1.600 mm specimens. Results indicated that quantities such as pit surface area and surrounding pit proximity are as important as pit depth in determining when and where a crack will form.     

Improving the corrosion protection of aluminium alloys using reactive magnetron sputtering

Most high strength aluminium alloys used in the aircraft industries are susceptible to corrosion. Up to now hexavalent chromium is the conventional corrosion inhibitor. Because chromium in hexavalent state is carcinogenic, it is necessary to develop effective alternative inhibitor systems. We investigated magnetron sputtered substoichiometric and stoichiometric aluminium nitride (AlN_x with x ? 1) coatings for corrosion protection of aluminium alloys 2024-T3, 6061-T4 and 7075-T6. The corrosion behaviour of the treated surfaces was tested by anodic polarization scanning and salt spray testing.From the polarization curves it can be concluded that magnetron sputter coating with AlN_x leads to a higher pitting potential of the three aluminium alloys investigated. The salt spray tested samples also confirm the protective effect of the coatings. In addition we found that AlN_x layers with high nitrogen content lead to a stronger shifting in pitting potential than those with low nitrogen content. Anyway, the results of the salt spray testing show that particularly nitrogen-rich AlN_x layers are less stable towards NaCl electrolyte.     

The influence of artificial aging on the microstructure,mechanical properties,corrosion, and environmental cracking susceptibility of a 7075 friction-stir-weld

The influence of overaging to the T7451 temper on the microstructure, the mechanical properties, and the corrosion susceptibility of friction-stir-welded 7075 aluminum alloy was investigated by means of transmission electron microscope (TEM), SEM investigations, constant extension rate tests (CERT), alternate immersion tests, and potentiodynamic scans. The overaging that occurs during welding within the heat-affected zones of the friction-stir-welded 7075-O tempered plates promotes a slight formation of intragranular and grain boundary precipitates and increases the mechanical as well as the corrosion resistance properties as compared to the T7451 welded plates. The “double” overaging treatment, consisting of the T7451 temper and the thermal transient experienced by the heat-affected zones of the 7075-T7451 welded plates, increases the size of the intragranular and the grain boundary precipitates as well as the precipitate-free zones. These facts decrease the mechanical and corrosion properties of the 7075-T7451 weld. The T7451 thermal treatment applied after the welding of the 7075-O plates promotes the high presence of small precipitates and reduces the size of the precipitate-free zones. This fact increases the general corrosion resistance, but decreases the mechanical properties. Therefore, the corrosion as well as the mechanical properties are greatly correlated with minute changes in the microstructure, which can arise by short-term heat exposure as for instance during welding. It was also found that the environmental susceptibility measured by means of CERTs may be influenced by “solution-strengthening” corrosion mechanisms which increase the strain. This fact is present in weld microzones particularly susceptible to corrosion.     

The effect of molybdenum ion implantation on the general and pitting corrosion behaviour of pure aluminium and a high strength aluminium alloy

The effect of Ar and Mo ion implantation on the corrosion behaviour of pure Al and a high strength aluminium alloy (7075-T6) has been investigated in Cl^?-free and Cl^?-containing sulphate solutions. In Cl^?-free environments, Mo implantation markedly affects the general corrosion behaviour of both the pure metal and the alloy. Ar implantation, on the other hand, has no permanent effect on the potentiodynamic polarization behaviour of pure Al but does alter somewhat the polarization characteristics of 7075-T6. In Cl^?-containing environments, Mo implantation significantly improves the resistance of pure Al to pitting corrosion, and increases the breakdown potential by about 200 mV. A similar, though less marked effect is observed with the alloy. Ar implantation has no major effect on the behaviour of either the pure metal or 7075-T6 in Cl^?-containing environments. On the basis of Rutherford backscattering and potential-time measurements it is suggested that the beneficial effect of Mo may be due to either the incorporation of Mo in the passive film or to dissolution and reprecipitation of some Mo-containing species on the passive film.     

Fabrication and Characterisation of Rutile-TiO_2 Coatings on Metallic Alloy Substrates

RUTILE-TJO2is a versatile material possessing manyinteresting physical,chemical,optical and dielectricproperties[l].It is also a good tribological material thatcan offer low friction and low wear rate[2,3].However,the application of rutile in the tribological field hasbeen limited to titanium alloys only so far,for example,by thermal oxidation of titanium alloys[4,5].Very fewinvestigations have been directed to the tribologicalapplications of rutile films on substrates other thantitanium al…     

Slow strain rate testing of high-strength aluminium alloy plate in an aqueous solution of 3% NaCl + 0.3% H2O2

The stress corrosion cracking (SCC) behaviour of aluminium alloy plate materials was investigated in the short transverse direction using the slow strain rate (SSR) testing technique. The synthetic environment used was an aqueous solution of 3% NaCl + 0.3% H₂O₂. Reference tests under constant deformation and alternate immersion conditions according to ASTM G44 were performed, too. Both static and dynamic loading tests indicate high SCC susceptibility with the alloys 2024-T351, 2091-T8X51, 7050 T651 and 7475-T651. For the alloy 8090-T8171, a low SCC resistance is found in the alternate immersion tests, whereas a rather moderate sensitivity is observed performing SSR tests. The SSR testing technique fails to indicate the SCC sensitivity of the more resistant alloys 2024-T851 and 7050-T7651. As demonstrated by pre-exposure tests, the reduction of fracture energy observed with the latter alloys as well as with the immune alloys 7050-T7351 and 7475-T7351 is caused by pitting and intergranular corrosion. Using an aqueous solution of 3% NaCl + 0.3% H₂O₂, the SSR testing technique is a useful rapid method to screen wrought aluminium alloys which are quite sensitive to environmentally assisted cracking. Because chloride-peroxide solutions are also conducive to corrosion processes independent of stress, pre exposure tests are required to be incorporated into such sorting tests.