The role of silicon in the corrosion of AA6061 aluminium alloy laser weldments

The galvanic corrosion temporal increase observed on examination of the weld fusion zone (WFZ) of AA6061 laser weldments in 3.5 wt.% NaCl solution cannot be attributed to electron tunnelling as the surface oxide layer is too thick, or the presence of Cl⁻ within the surface layer as this element was not found to be present. Aluminium alloy and WFZ galvanic and surface analyses indicate that the cathodic WFZ corrosion characteristics are due to increases in silicate concentrations in the surface oxide layer, leading to increased ionic and/or p-type semi-conductor conductivity, intermetallic concentrations and surface area.     

In-situ investigation on the pitting corrosion behavior of friction stir welded joint of AA2024-T3 aluminium alloy

The surface corrosion behavior of an AA2024-T3 aluminium alloy sheet after friction stir welding was investigated by using an “in-situ observation” method. SEM observations showed that the density and degree of the pitting corrosion in the shoulder active zone were slightly larger compared to the other regions on the top surface. The origins of the pitting corrosion were in the regions between the S phase particles and the adjacent aluminium base. The effect of Al-Cu-Fe-Mn-(Si) intermetallic compounds on the pitting corrosion was attributed to their high self-corrosion potential which induced the anodic dissolution of the surrounding aluminium matrix.     

Influence of ultrasound on pitting corrosion and crevice corrosion of SUS304 stainless steel in chloride sodium aqueous solution

The change of polarization curves and surface morphologies of SUS304 stainless steel was investigated in 3.5 mass% NaCl solution with or without the application of ultrasound (US). As the result, both the pitting corrosion and the crevice corrosion were largely suppressed by the application of US. The reason is attributed to the decrease in the concentration of hydrogen and chloride ions in pits or in the crevice by removing the corrosion product and stirring the liquid there.     

双级时效对6061铝合金拉伸性能和晶间腐蚀性能的影响

采用拉伸试验、晶间腐蚀试验、金相及透射电镜观察,研究双级时效对6061铝合金拉伸性能和晶间腐蚀性能的影响。结果表明:6061铝合金经(180℃,8h)的T6峰值时效,抗拉强度和屈服强度分别为356MPa和331.6MPa,伸长率为13.7%,但出现严重的晶间腐蚀,腐蚀深度约为270μm。在T6峰值时效的基础上进一步升高温度和延长时间进行二级时效,合金强度总体上呈逐渐降低趋势,电导率逐渐上升,腐蚀类型也由晶间腐蚀逐渐转变为点蚀,腐蚀深度明显变浅。对于6061铝合金,最佳双级时效工艺为(180℃,8h)+(210℃,2h),抗拉强度为348.4MPa,屈服强度为320.3MPa,伸长率为11.3%,腐蚀类型为轻微点蚀,腐蚀深度约为50μm。     

Explanation of the effect of high chloride concentration on the critical pitting temperature of stainless steel

We correlate the effect of high chloride concentration on the critical pitting temperature (CPT) of type 316L stainless steel with its effect on the critical pit solution chemistry as determined by the artificial pit technique. It is shown that the change in CPT with bulk chloride concentration (0.5-9 mol kg⁻¹) can be correlated with a change in the ratio of C^∗/C_s, where C^∗ is the critical dissolved alloy cation concentration to sustain pitting, and C_s is the solubility of FeCl₂ at the pit surface. A complicating factor is that natural pits can only grow with C^∗ = C_s at the lower chloride concentrations, but can grow without the salt film at very high chloride concentrations; this transition is believed to occur close to 5 or 6 m bulk chloride concentration. The dependence of C_s on bulk chloride concentration is given a new interpretation based on a common-ion effect operating within an altered local chemistry with complexation.     

Role of water, acetic acid and chloride on corrosion and pitting behaviour of carbon steel in fuel-grade ethanol

The role of water, acetic acid, chloride, and oxygen level in corrosion and pitting behaviour of carbon steel in simulated fuel-grade ethanol (SFGE) was investigated. In the absence of the supporting electrolyte, modified cell geometry enabled us to conduct the electrochemical measurement in low-conductivity ethanolic solutions. Results have shown that the water in the SFGE strongly influences the surface film stability and interface electrochemistry in ethanolic environments. The increase in the water concentration induces pitting and metal loss. Dissolved chlorides and higher acidity promote the pit initiation and growth. Alkaline condition inhibits both localized and uniform corrosion.     

Microstructure and pitting corrosion of friction stir welded joints in 2219-O aluminum alloy thick plate

Effect of welding parameters on the microstructure and pitting corrosion of different positions along the thickness of weld nugget zone in friction stir welded 2219-O aluminum alloy plate was investigated using scanning electron microscopy (SEM), polarization experiment and electrochemical impedance tests (EIS). It was found that the material presents significant passivation and the top has best corrosion resistance compared to the bottom and base material. Corrosion resistance decreases with the increase of traverse speed from 60 to 100 mm/min at rotary speed 400 rpm. Corrosion resistance at rotary speed 600 rpm is lower than that at 500 rpm.     

On the chloride-induced pitting of ultra fine grains 5052 aluminum alloy produced by accumulative roll bonding process

Pitting corrosion susceptibility of ultra fine grain (UFG) 5052 aluminum alloy (AA 5052) sheets highly deformed by accumulative roll-bonding (ARB) was investigated in 3.5 wt% NaCl solution using potentiodynamic polarization, cyclic voltammetry and immersion tests. The morphology of localized attacks was analyzed by SEM-EDS. Pitting corrosion resistance of samples was diminished with increasing the number of ARB passes which is presumably due to microstructure refinement and increasing the defect density.     

Prior corrosion and fatigue of 2024-T3 aluminum alloy

Pit-to-crack transition experiments were conducted on two thicknesses of 2024-T3 aluminum alloy. Specimens were corroded using a 15:1 ratio of 3.5% sodium chloride solution and hydrogen peroxide prior to fatigue loading. Cracks originating from corrosion pits were visually investigated using various microscopy techniques in order to gain insight into the pit-to-crack transition process.All pre-corroded specimens in this study fractured from cracks associated with pitting. Pit-to-crack transition was successfully observed using digital video techniques. The more aggressively corroded 2024-T3-4.064 mm specimens experienced more of an overall fatigue life reduction than 2024-T3-1.600 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.     

Effect of prior corrosion on short crack behavior in 2024-T3 aluminum alloy

Two thicknesses of dogbone shaped 2024-T3 aluminum alloy specimens were notched and corroded prior to constant amplitude fatigue loading. The purpose of the subject research was to examine and characterize the effects of various levels of prior corrosion on the growth rate of short fatigue cracks. The specimens were notched and exposed to a corrosive environment per one of three defined protocols prior to experimentation. The notch was manually introduced at one edge of the test section of the specimen, which was later corroded to create a more natural site for crack origination. Fatigue crack nucleation was monitored and subsequent crack growth recorded, with results presented in the form of da/dN vs. ΔK curves.     

Comparison of corrosion pitting under immersion and salt-spray environments on an as-cast AE44 magnesium alloy

The corrosion mechanisms of pitting, intergranular corrosion, and general corrosion were examined on an AE44 magnesium alloy subjected to immersion and salt-spray environments. The two environments show similar trends with respect to weight loss and thickness loss, although the immersion environment induces greater amounts of weight loss of magnesium. With respect to the corrosion mechanisms, the two environments show definitive trends, owing to the continuous presence of water in the immersion environment allowing more and larger pits to form as compared to the salt-spray environment. The immersion environment was more deleterious than the salt-spray environment for magnesium.     

Effect of solution treatment on the corrosion behaviour of aluminium alloy AA7150: Optimisation for corrosion resistance

Studies for Al-alloys normally employ specimens subject to a fixed solution heat treatment (SHT), and hence the specific role of solutionising is overlooked. It is revealed that SHT has a major role in corrosion of AA7150 as judged by electrochemical, microscopic and profilometry studies. SHT dictates the constituent particle type and population remaining in the alloy for subsequent processing, and is thus not only a principal factor in corrosion, but a factor that can be engineered in developing more damage tolerant AA7150. Effect of an optimised SHT minimising the residual MgZn₂ and Al₂MgCu content on corrosion resistance is demonstrated.     

Microstructure and pitting corrosion of 13CrNiMo weld metals

Cyclic potentiodynamic measurements and scanning electron microscopy were used to analyze susceptibility to pitting corrosion of 13CrNiMo weld metals. In order to carry out a critical assessment of the influence of microstructural factors on localized corrosion, different heat treatments were applied to the alloys under investigation. Volume fractions of austenite in tempered conditions as well as the amount and size of precipitated carbides strongly affect pitting resistance. Characteristic potentials (pitting potential and repassivation potential) increase according to the retained austenite content. Results can be discussed in terms of a model that describes the structural refinement resulting from a double-tempering procedure.     

Critical pitting temperature dependence of 2205 duplex stainless steel on dichromate ion concentration in chloride medium

In this study, the influence of various concentrations of dichromate and chloride ions on critical pitting temperature (CPT) of duplex stainless steel 2205 (DSS 2205) is investigated by employing potentiodynamic and potentiostatic CPT measurement methods. Potentiostatic results indicate that by adding 0.01 M to 0.1 M NaCl solution the CPT raised by 12 °C. Based on potentiodynamic CPT measurements in the solutions with ratio equal to one for solutions containing 0.1 M NaCl + 0.1 M and 0.01 M NaCl + 0.01 M , no CPT was detected up to 75 °C.     

Structure–property quantification of corrosion pitting under immersion and salt-spray environments on an extruded AZ61 magnesium alloy

Extruded AZ61 magnesium coupons were exposed to immersion and cyclical salt spray environments over 60 h in order to characterize their corrosion rates. The characteristics of general corrosion, pitting corrosion, and intergranular corrosion were quantified at various intervals. General corrosion was more prevalent on the immersion surface. In addition, more pits formed on the immersion surface due the continuous exposure to water and chloride ions. However, the pits on the salt spray surface showed larger surface areas, larger volumes, and covered more area on the micrographs as compared to the pits on the immersion surface, due to the dried pit debris that trapped chloride ions within the pits.     

Relationship between microstructure and corrosion performance of AA2050-T8 aluminium alloy after excimer laser surface melting

Surface modification by excimer laser surface melting (LSM) has been performed with the aim to improve the corrosion resistance of the AA2050-T8 alloy. LSM produced melted surfaces, largely free of precipitates, with both microstructure and corrosion behaviour depending upon the number of laser pulses employed. Increased number of laser pulses resulted in thicker melted layers, but also in greater trapped porosity and formation of micro-cracks at the overlapping area. Nevertheless, the LSM-treated specimens exhibited enhanced corrosion resistance compared to the untreated alloy, which was associated with the formation of a relatively uniform melted layer and a diminished presence of precipitates.     

Structural and electrochemical performance of sputtered Al–Ce films on AA6061 aluminum alloy substrates

In this work, sputtered Al–Ce films were studied in order to evaluate their possible application as coatings to delay pitting corrosion of aluminum alloy substrates. The morphology and structure of the coatings deposited on both silicon and AA6061 aluminum alloy substrates were studied by varying the magnetron sputtering conditions. The preliminary electrochemical performance was also discussed by means of Tafel plots and electrochemical impedance spectroscopy (EIS). The X-ray diffraction studies indicated that the microstructure varied from crystalline to amorphous, depending on the deposition parameters. The AFM images show that the films consist of equi-axial round domes distributed homogeneously. The mean grain size, roughness and thickness of the coatings were increased by augmenting the power and pressure. The EIS studies showed that there was a significant increase in the resistance to corrosion after depositing Al–Ce films on AA6061 aluminum alloy substrates. The electrochemical behavior of the films was related to the Ce/Al composition ratio as well as process parameters.     

Stochastic modeling of pitting corrosion: A new model for initiation and growth of multiple corrosion pits

In this work, a new stochastic model capable of simulating pitting corrosion is developed and validated. Pitting corrosion is modeled as the combination of two stochastic processes: pit initiation and pit growth. Pit generation is modeled as a nonhomogeneous Poisson process, in which induction time for pit initiation is simulated as the realization of a Weibull process. In this way, the exponential and Weibull distributions can be considered as the possible distributions for pit initiation time. Pit growth is simulated using a nonhomogeneous Markov process. Extreme value statistics is used to find the distribution of maximum pit depths resulting from the combination of the initiation and growth processes for multiple pits. The proposed model is validated using several published experiments on pitting corrosion. It is capable of reproducing the experimental observations with higher quality than the stochastic models available in the literature for pitting corrosion.     

6061铝合金搅拌摩擦焊焊接接头应力腐蚀的敏感性

采用慢应变速率拉伸(SSRT)方法分析6 mm厚的6061-T6铝合金及其搅拌摩擦焊接头在模拟海水溶液及空气中的应力腐蚀敏感性,测试和分析搅拌摩擦焊接头金相组织、显微硬度和断口形貌。结果表明,焊核区晶粒细小,热机影响区晶粒出现弯曲及拉长变形,热影响区晶粒粗大。接头显微硬度值呈"W"型分布,其最大值为71.8 HV。在应变速率为1×10-6/s时,接头及母材在3.5%Na Cl溶液中具有应力腐蚀敏感性,接头应力腐蚀敏感性高于母材。     

Galvanic corrosion of laser weldments of AA6061 aluminium alloy

Galvanic corrosion of laser welded AA6061 aluminium alloy, arising from the varying rest potentials of the various weldment regions, was examined. The weld fusion zone is found to be the most cathodic region of the weldment while the base material is the most anodic region. The rate of galvanic corrosion, controlled by the cathodic process at the weld fusion zone, increases with time until a steady state maximum is reached. On galvanic corrosion the corrosion potential of the weld fusion zone shifts in the positive direction and the free corrosion current increases. It is proposed that the cathodic process at the weld fusion zone causes a local increase in pH that in turn causes dissolution of the surface film resulting in the loss of Al to solution and the increase of intermetallic phases. The increase in galvanic corrosion may result from either the build up of the intermetallic phases in the surface layer and/or significant increase in surface area of the weld fusion zone due to the porous nature of the surface layer.