Wear of Al/Al3Zr functionally graded materials fabricated by centrifugal solid-particle method

In this study, Al–5mass%Zr functionally graded materials (FGMs) were fabricated by the centrifugal solid-particle method (CSPM) under applied centrifugal force of 30, 60 and 120G (units of gravity). Microstructural observation along the centrifugal force direction showed that Al₃Zr platelet particles are almost oriented normal to the applied centrifugal force direction. Volume fraction of Al₃Zr particles increases close to the ring surface. Moreover, this distribution range of Al₃Zr particles becomes broader with decreasing the applied centrifugal force. The wear anisotropy of the fabricated Al/Al₃Zr FGMs was strongly influenced by the platelet particles orientation at the test position. Investigating both of the worn surface morphology and the sub-worn surface layer showed that plastic deformation induced wear is the dominant mechanism during the wear process of Al/Al₃Zr FGMs samples. Therefore, some of the tested samples were severely deformed and an Al₃Zr particles-free layer containing Al–Zr supersaturated solid solution was observed very near to the worn surface during the wear test.     

The effects of lanthanum on microstructure and electrochemical properties of Al–Zn–In based sacrificial anode alloys

In order to improve the non-uniform corrosion of Al–0.5Zn–0.03In–1Mg–0.05Ti alloys, Al–5Zn–0.03In–1Mg–0.05Ti–xLa (x = 0.3, 0.5 and 0.7 wt.%) alloys were developed. Microstructures and electrochemical properties of the alloys were investigated. The results show that the optimal microstructures and electrochemical properties are obtained in Al–5Zn–0.03In–1Mg–0.05Ti–0.5La alloy. The main precipitate phase is Al₂LaZn₂ particles. The excellent electrochemical properties of Al–5Zn–0.03In–1Mg–0.05Ti–0.5La alloy is mainly attributed to fine grains and grain boundaries containing fine Al₂LaZn₂ precipitates. At the same time the fine grains can improve the non-uniform corrosion of Al–0.5Zn–0.03In–1Mg–0.05Ti alloy.     

Influence of silicon on the corrosion behaviour of Al–Zn–In–Mg–Ti sacrificial anode

The influence of Si on the corrosion behaviour of Al–5Zn–0.03In–1Mg–0.05Ti (wt.%) alloy was investigated by the microstructure observation and electrochemical measurements in order to improve its corrosion non-uniform and electrochemical properties. The main precipitates in Al–5Zn–0.03In–1Mg–0.05Ti–0.1Si (wt.%) alloy is Mg₂Si phase, which decrease the galvanic corrosion because the potential difference between Mg₂Si and a-Al is smaller than that between MgZn₂ and a-Al. The addition of Si improves the corrosion uniformity of the anode due to the fine equiaxed grains and grain boundaries where Mg₂Si particles uniformly distributed. The results indicate that the microstructure, electrochemical characteristics and corrosion uniformity can be improved significantly after adding 0.1 wt.% Si into Al–5Zn–0.03In–1Mg–0.05Ti (wt.%) alloy.     

Microstructures and wear resistances of hybrid Al–(Al3Ti+Al3Ni) FGMs fabricated by a centrifugal method

The Al based functionally graded materials (FGMs), reinforced by a hybrid of Al₃Ti platelets and Al₃Ni granular particles, were fabricated by the centrifugal method with both ingots of commercial Al–5mass%Ti and Al–20mass%Ni master alloys. The ratios of Al–Ti and Al–Ni alloys were 3:1, 1:1 and 1:3 (in mass), and the applied G numbers are 30, 50 and 80. The microstructures of hybrid Al–(Al₃Ti+Al₃Ni) FGMs were observed with an optical microscope (OM) and a scanning electron microscope (SEM). Since the gradient distributions in orientation of Al₃Ti platelets and in particle size of Al₃Ni primary crystal particle were expected to be formed in the fabricated hybrid Al–(Al₃Ti+Al₃Ni) FGMs, detail observations of the orientation of Al₃Ti platelets and the size of Al₃Ni granular particles were performed. The wear resistance of the FGMs was measured by an Okoshi-type wear machine. Based on the experimental results, the advantages of hybrid Al–(Al₃Ti+Al₃Ni) FGMs were discussed.     

Effect of sintering temperature on corrosion properties of sol–gel based Al2O3 coatings on pre-treated AZ91D magnesium alloy

A novel anti-corrosion sol–gel based Al₂O₃ coating was developed on the AZ91D magnesium alloy. The morphology, microstructure and composition of the coatings were investigated by scanning electron microscope coupled with energy dispersive spectroscopy, Fourier transform infrared spectrum analysis, X-ray diffraction, thermo-gravimetric and differential thermal analysis. The corrosion resistance of the coatings in 3.5 NaCl wt.% solution was studied using electrochemical measurements. The results demonstrated that a homogeneous Al₂O₃ coating could be obtained and the sol–gel coated samples sintered at 380 °C had the best corrosion resistance properties as compared to the specimens sintered at 120 and 280 °C.     

Anodic dissolution of Al sacrificial anodes in NaCl solution containing Ce

The corrosion behaviour of Al–Zn–In sacrificial anodes has been investigated in a sodium chloride solution containing CeCl₃. Scanning electron microscopy, energy-dispersive X-ray analysis, and inductively coupled plasma mass spectrometry have been employed to gain knowledge of the micro-morphology and corrosion process of the Al alloy. Cerium, both as the alloy element and as the additive in the NaCl solution, improves the electrochemical properties of the Al–Zn–In alloy. The activation of Ce in the Al–Zn–In alloy in the NaCl solution has been studied.     

Microstructure, spallation and corrosion of plasma sprayed Al2O3–13%TiO2 coatings

The electrochemical corrosion behaviours of the steel substrates coated with three different plasma sprayed Al₂O₃–13%TiO₂ coatings were studied in this paper. The three kinds of Al₂O₃–13%TiO₂ coatings were conventional ME coating, nanostructured NP coating and NS coating. There were micro cracks, laminar splats and straight columnar grains in ME coating. For the two nanostructured coatings, the laminar microstructure and columnar grains were not obvious. The NP coating had the highest hardness and spallation resistance. Electrochemical corrosion behaviour of the three coatings was mainly investigated by potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) in aqueous Na₂SO₄ solution.     

Al–Ti–B grain refiners via powder metallurgy processing of Al/K2TiF6/KBF4 powder blends

The response to thermal exposure of ball-milled Al/K₂TiF₆/KBF₄ powder blends was investigated to explore the potential of PM processing for the manufacture of Al–Ti–B alloys. K₂TiF₆ starts to be reduced by aluminium as early as 220 °C when ball-milled Al/K₂TiF₆/KBF₄ powder blends are heated. The reaction of KBF₄ with aluminium follows soon after. The Ti and B thus produced are both solutionized in aluminium before precipitating out as Al₃Ti and TiB₂. All these reactions take place below the melting point of aluminium. The ball-milled Al/K₂TiF₆/KBF₄ powder blends heat treated at approximately 525 °C can be compacted to produce Al–Ti–B pellets with in situ formed Al₃Ti and TiB₂ particles. These pellets are shown to be adequate grain refiners for aluminium alloys.     

Modelling the corrosion behaviour of Al2CuMg coarse particles in copper-rich aluminium alloys

The corrosion behaviour of 2024 aluminium alloy in sulphate solutions was studied; attention was focused on the influence of coarse intermetallic Al₂CuMg particles on the corrosion resistance of the alloy. Model alloys representative of the aluminium matrix and of Al₂CuMg coarse intermetallics were synthesized by magnetron sputtering. Open-circuit potential measurements, current-potential curve plotting and galvanic coupling tests were performed in sulphate solutions with or without chlorides. Further explanations were deduced from the study of the passive films grown on model alloys in sulphate solutions. The results showed that model alloys are a powerful tool to study the corrosion behaviour of aluminium alloys.     

Al2O3-ZrO2 mixed oxide composite incorporated aluminium rich zinc coatings for high wear resistance

Corrosion resistance and wear resistance are the two important parameters for high performance of zinc galvanic coating. In the present work, the improvement of these two characteristics was achieved by the incorporation of Al₂O₃-ZrO₂ mixed oxide composite in the coating. Al₂O₃-ZrO₂ mixed oxide composite was synthesized from ZrOCl₂·8H₂O. Aluminium rich zinc coatings with high sliding wear resistance was developed from a galvanic bath containing the mixed oxide. Based on the performance of the coating during physicochemical and electrochemical characterization, the concentration of mixed oxide composite in the bath was optimized as 0.50 wt% Al₂O₃-0.50 wt% ZrO₂. While rich in Al-metal content in the coating caused high corrosion resistance, the incorporation of the mixed oxide improved structural characteristics of the coating resulting in high wear resistance also. The coating was nonporous in nature and even the interior layers had high stability. The coatings have potential scope for high industrial utility.     

Composition and processing effects on the electrochemical characteristics of biomedical titanium alloys

The electrochemical behaviour of the Ti–13Nb–13Zr and Ti–6Al–4V ELI alloys with martensitic microstructures was investigated by polarization and electrochemical impedance spectroscopy (EIS) in Ringer’s solution. The impedance spectra were interpreted by a two time-constants equivalent circuit. Both investigated alloys showed high corrosion resistance, but the thin and uniform passive film on the Ti–6Al–4V ELI alloy surface was more protective. The inner barrier and outer porous layer were highly resistant and capacitive. However, thicker and more porous passive film on the Ti–13Nb–13Zr alloy surface may be beneficial for osteointegration. The suitable thermomechanical processing improved the corrosion resistance of Ti–13Nb–13Zr alloy.     

Microstructure effects on the electrochemical corrosion properties of Mg – 4.1% Ga – 2.2% Hg alloy as the anode for seawater-activated batteries

Mg–Ga–Hg alloy is a new material with special electrochemical corrosion properties that make it ideal for use in seawater-activated battery anodes. The effects of microstructure and phase transformation on the electrochemical properties of the Mg – 4.1% Ga – 2.2% Hg alloy were studied and compared with Mg–Al system alloys. The results show that the Mg – 4.1% Ga – 2.2% Hg alloy, when used as an anode, has an appropriate corrosion potential in a half-cell test and superior electrochemical properties in a single cell assembled with CuCl. The Mg₃Hg and Mg₂₁Hg₅Ga₃ phases of the alloy influence its corrosion behaviour and provide a steady corrosion potential during the discharge process.     

Precipitation kinetic of Al3(Sc,Zr) dispersoids in aluminium

The non-isothermal formation of Sc- and Zr-containing dispersoids in Al–Zr–Sc ternary alloys has been investigated by atom probe tomography (APT). In the early stages of precipitation, a high number density of Sc-rich clusters form. These clusters subsequently transform into Al₃Sc particles with a L1₂ structure. When Zr diffusion becomes significant, Zr atoms are found to segregate to Al₃Sc/α-Al matrix interfaces. Further annealing at 748 K gives rise to a duplex core/shell structure.     

Ti6Al4V钛合金表面Al2O3颗粒改性微弧氧化涂层制备及性能

微弧氧化技术是一门新的表面处理技术,在很多领域有着广泛的应用前景,但其结构受限于电解液成分。本文通过在磷酸盐电解液中加入Al2O3陶瓷颗粒,使得在Ti6Al4V钛合金表面的微弧氧化涂层结构和性能得到改性。涂层的结构和性能通过扫描电镜和XRD衍射仪进行表征和测试,涂层的抗高温氧化性能和热震性能通过高温热循环氧化试验和热震试验进行测试。结果表明,通过在电解液中添加Al2O3陶瓷颗粒,涂层由Al2TiO5 and TiO2组成,涂层更为致密,表现出更为优异的抗高温氧化和热震性能。电解液中游动的Al2O3陶瓷颗粒在微弧氧化过程中被吸入到样品表面并进入涂层,涂层的结构和性能得到改性。     

Passivation of Al–Cr–Fe and Al–Cu–Fe–Cr complex metallic alloys in 1 M H2SO4 and 1 M NaOH solutions

The corrosion mechanisms of Al–Cr–Fe and Al–Cu–Fe–Cr complex metallic alloys have been investigated by potentiodynamic and potentiostatic polarization. Very good passivation of the Al–Cr–Fe surface is exhibited from 1 M H₂SO₄ to 1 M NaOH solutions, which was confirmed by ICP-OES analysis over a period of 273 days. Potentiostatically formed passive films analysed by XPS revealed chromium enrichment in the outermost layer of the aluminium oxy-hydroxide film. Although Al–Cu–Fe–Cr showed passivation during potentiodynamic polarization, heavy active corrosion at OCP was revealed by ICP-OES. For the Al–Cu–Fe–Cr alloy, the 10% content of Cr is insufficient to maintain a protective “chemically stable” Cr oxide/hydroxide.     

Electrochemical corrosion behavior of Mg-5Al-0.4Mn-xNd in NaCl solution

The electrochemical corrosion behavior of Mg-5Al-0.4Mn-xNd (x = 0, 1, 2 and 4 wt.%) alloys in 3.5% NaCl solution was investigated. The corrosion behavior of the alloys was assessed by open circuit potential measure, potentiodynamic polarization, and electrochemical impedance spectroscopy. The electrochemical results show the intermetallic precipitates with Nd behave as less noble cathodes in micro-galvanic corrosion and suppress the cathodic process. During corrosion, Al₂O₃ and Nd₂O₃, in proper ratio, is incorporated into the corrosion film, and enhances the corrosion resistance.     

Discontinuities in the porous anodic film formed on AA2099-T8 aluminium alloy

The anodizing behaviour of constituent particles (Al–Fe–Mn–Cu) and dispersoids (Al–Cu–Mn–Li and β′(Al₃Zr)) in AA2099-T8 has been investigated. Low-copper-containing Al–Fe–Mn–Cu particles anodized more slowly than the alloy matrix, forming a highly porous anodic oxide film. Medium- and high-copper-containing Al–Fe–Mn–Cu particles were rapidly dissolved, resulting in defects in the anodic film. The anodizing of Al–Cu–Mn–Li dispersoids is slightly slower than the alloy matrix, forming a less regular anodic oxide film. β′(Al₃Zr) dispersoids anodized at a similar rate to the alloy matrix. Further, the potential impact of the discontinuities in the resultant anodic films on the performance of the filmed alloy is discussed.     

In situ formation of various intermetallic particles in Al–Ti–X(Cu,Mg) systems during friction stir processing

In situ Al composites reinforced by various intermetallic particles were fabricated from Al–Ti–X(Cu, Mg) systems by hot pressing, forging and subsequent 4-pass friction stir processing (FSP). The formation of various intermetallic particles during FSP and the tensile properties of in situ composites were investigated. For Al–Ti–Cu system, Cu enhanced the Al–Ti reaction and resulted in the formation of more Al₃Ti particles due to the presence of a small amount of liquid phase during FSP. After FSP, part of Cu was kept in the Al matrix as solute, whereas the other formed Al₂Cu particles. For Al–Ti–Mg system, except for Al₃Ti, some Ti₂Mg₃Al₁₈ particles with fine twin lamellas were formed during FSP, resulting in an increase in the total volume fraction of reinforcing particles. Cu and Mg addition increased the strength of the in situ composites substantially due to introduction of more strengthening modes and more reinforcing particles, however the elongation decreased dramatically.     

Microstructures of functionally graded materials fabricated by centrifugal solid-particle andin-situ methods

Functionally graded materials (FGMs) belong to a relatively new class of inhomogeneous composite materials, in which the composition and/or microstructure undergo a gradual change along some directions. In this review article, the microstructures and composition gradients in Al/SiC, Al/Shirasu (volcanic eruptions commonly found in south Kyushu in Japan), Al/Al₃Ti, Al/Al₃Ni, Al/Al₂Cu FGMs have been investigated. The Al/SiC, Al/Shirasu and Al/Al₃Ti FGMs are fabricated by the centrifugal solid particle method where the distribution particles of SiC, Shirasu and Al₃Ti are solids in the melts. On the other hand, Al/Al₃Ni and Al/Al₂Cu FGMs are fabricated by the centrifugalin-situ method where Al/Al₃Ni and Al/Al₂Cu systems have lower liquidus temperatures than the processing temperatures. The feature of Al/(Al₃Ti−Al₃Ni) hydrid FGM, which is fabricated by a method combining both the centrifugal solid-particle andin-situ methods, is also shown.     

Electrochemical behavior and localized corrosion associated with Al7Cu2Fe particles in aluminum alloy 7075-T651

Initiation of localized corrosion upon high strength aluminum alloys is often associated with cathodic intermetallic particles within the alloy. Electrochemical measurements and metallurgical characterization have been made to clarify and quantify the physical properties of Al₇Cu₂Fe particles in AA7075-T651. Prior studies regarding either the stereology or electrochemical properties of Al₇Cu₂Fe are scarce. Quantitative microscopy revealed a significant population of Al₇Cu₂Fe in the alloy; comprising up to 65% of the constituent particle population and typically at a size of 1.7 ± 1.0 μm. It was determined that Al₇Cu₂Fe may serve as a local cathode in the evolution of localized corrosion of AA7075-T651 and is capable of sustaining oxygen reduction reactions at rates of several hundreds of μA/cm² over a range of potentials typical of the open circuit potential (OCP) of AA7075-T651 in NaCl solution of various concentrations and pH. The presence of Al₇Cu₂Fe leads to the development of pitting at the particle–matrix interface.