Verhalten von Magnesiumlegierungen für Anwendungen im Fahrzeugbau bei mechanisch‐elektrochemischer Komplexbeanspruchung: Einfluss passivierender Deckschichten und Mechanismen der lokalen Schädigung

Behavior of Magnesium‐Alloys for Automotive Applications under Mechanical and Environmental Loading: Influence of Passivating Films and Mechanisms of Local Breakdown To assure an efficient design of components under cyclic loading, all available data concerning fatigue have to be observed. Therefore the influences of manufacturing on the material condition, the mechanical loads and environmental effects have to be analysed. Magnesium‐alloys are of special interest for lightweight applications because of their excellent strength‐density ratio. The corrosion resistance of magnesium‐alloys depends on the same factors that are critical to other metals. The alloys have a good stability to atmospheric exposure and a good resistance to attack by alkali, chromic and hydrofluoric acids. However, because of the electrochemical activity of magnesium, the relative importance of some factors is greatly amplified. The nature and composition of passive films formed on magnesium‐alloys depend on the prevailing conditions, viz. alloy‐composition, passivation potential, pH, electrolyte composition and temperature. Passive films may be damaged by local breakdown. Because of this, magnesium‐alloys suffer a degradation of their properties when exposed to an aqueous environment. The main topic of the present investigations is the verification of mechanisms of the local breakdown of the protecting film. At least two mechanisms are possible for this localization: mechanical breakdown by slip steps and electrochemical breakdown (for e.g. by the effects of chloride ions). Corrosion and passivation of different high purity alloys have been studied in different solutions (neutral, alkaline with specific anions and cations) using electrochemical techniques. The diecasted alloys were tested as produced and machined. The results clarified that depending on alloy/material and surface condition/corrosion environment different mechanisms for electrochemical breakdown of the protecting films are possible. Hence fatigue life under environmental loading is influenced by surface and testing conditions.     

Production and properties of micro‐porous glas bubble zinc and aluminium composites

Micro‐porous syntactic foams were produced by means of integration of glass bubbles into aluminium and zinc matrices. Preforms of glass bubbles were pressure infiltrated with the alloys AlSi9Cu9 ans ZnAl4Cu using squeeze casting. The preforms were sintered thermically without the use of bonding agents. Using the combination of different sintering steps syntactic foams with locally different densities could be produced. The mechanical properties of the foams were tested indicating a high compression strength of the foams and a very good compression energy absorption. Furthermore, corrosion behaviour and behaviour at higher temperatures were investigated.     

The influence of NaCl and CO2 on the atmospheric corrosion of magnesium alloy AZ91

The influence of NaCl and CO₂ on the atmospheric corrosion of magnesium alloy AZ91 is studied in the laboratory. Samples were exposed under carefully controlled air and flow conditions; the relative humidity was 95%, the temperature was 22.0°C and the concentration of CO₂ was < 1 ppm or 350 ppm. Different amounts of sodium chloride (0–70 μg/cm²) were added before exposure. The corrosion products were analyzed by gravimetry, ion chromatography, X‐ray diffraction and scanning electron microscopy. Mass gain and metal loss results are reported. The combination of high humidity and NaCl is very corrosive towards AZ91. However, the NaCl‐induced corrosion is inhibited by ambient concentrations of CO₂. Exposure in the absence of CO₂ gives rise to heavy pitting, with brucite, Mg(OH)₂, being the dominant corrosion product. In the presence of CO₂ a layer of hydrated magnesium hydroxy carbonate, Mg₅(CO₃)₄(OH)₂ · 5 H₂O forms. A tentative corrosion mechanism is presented that explains the behavior in the two environments.     

Dental amalgam – the effect of the technology of alloy powder preparation on the corrosion behaviour and the release of mercury

Dental amalgams are based on a broad spectrum of materials differing in their chemical composition, metallurgical treatment, and in the way the initial alloys powders are prepared. In addition to their chemical composition, amalgams based on various powders differ in both their microstructure and the amount of mercury needed for preparation. All these facts may affect electrochemical processes occurring during their interaction with oral fluids, and also mercury release. While verifying the effect of the technology used for the preparation of the high‐copper ternary alloy powder on the properties of resulting amalgams, this study aimed at the mechanism of their interaction with a model saliva solution as well as mercury release was included. Measurements were done in a model saliva solution using standard electrochemical methods and exposition measurements. The interaction of individual types of amalgams with artificial saliva did not reveal any significant differences. The free corrosion potential of all these amalgams in an aerated solution settled in the range of values in which tin oxidation, resulting in a layer of insoluble corrosion producsts, turned out to be the dominant anodic process. The rate of mercury release was the lowest for amalgams based on a gas‐atomized alloy. The highest rate of mercury release, and also its dependence on time, was exhibited by lathe‐cut powder based amalgam. In addition to different volume fraction of the Ag‐Hg phase and the level of its tin alloying, this different behaviour may be explained by differences in the rate at which a layer of tin corrosion products acting as a barrier to mercury release is formed.     

Environmental fatigue behavior of non‐crimp,E‐glass fiber reinforced polyester composites for marine applications

This study is aimed to find the fatigue behavior of Glass Reinforced Plastics, a material which is a widely preferred material for small marine crafts, as well as several other applications. The type of composite tested is hand‐laid E‐glass non‐crimp reinforcements with an polyester resin matrix. The specimens were produced in two standard thicknesses and with these material directions and were tested both under atmospheric and simulated seawater environments for fatigue. It was seen that the results of fatigue lifetime obtained by testing the material in seawater is much lower than the results obtained from testing similar specimens under atmospheric conditions. However, the stress curves indicate the same slope, suggesting that the fatigue failure mechanism of both testing conditions is the same and the fiber‐related factors dominate. It was found that the thickness and material direction did not have a significant effect on the fatigue behavior of the material.     

Fatigue performance of friction stir welded Al2024 alloy in a different corrosive environment

The study examines the corrosion fatigue behavior of friction stir welded Al2024 alloy in the corrosive medium. The fatigue tests are conducted at a stress ratio of -1 in the different corrosive medium. The decrease in the fatigue life of welded joints in the corrosive environment is attributed to an increase in the crack initiation susceptibility in the presence of corrosive media. The fractured surfaces are investigated using the scanning electron microscopy (SEM). The formation of the corrosive compounds was studied using x-ray diffractometry.     

Electrochemical sensors for biofilm and biocorrosion

The presence of biofilm modifies the electrochemical properties of the interface and the mass transport near the interface. Two biofilm effects are damageable: the reduction of heat and/or mass transfer and the biocorrosion or microbiologically influenced corrosion (MIC). Two kinds of electrochemical sensors were developed: the first kind for the biofilm detection and the second one to evaluate the MIC risk. The biofilm detection is obtained by considering either the potential modification of the interface or the mass transport modification. The mass transport modification is analysed by considering the limiting diffusion current measured on a gold electrode where the biofilm development occurs. The MIC risk is evaluated with a sensor composed of two concentric electrodes in the material under investigation (e.g. carbon steel): a small disk electrode in the centre and a large ring. In a first step, a pit is artificially initiated by applying a current through these electrodes. In a second step, the risk factors of MIC are investigated by analysing the free coupling current circulating between these two short‐circuited electrodes.     

Design of wear and corrosion resistant PVD‐coatings for magnesium alloys

Although magnesium alloys became popular in the first half of the 20^th century, the bad corrosion properties prevented their breakthrough in industrial mass production. Since the technology for the production of high purity alloys was introduced in the 1970s, magnesium alloys became more and more in the focus of industrial attention. Today magnesium alloys are state of the art in structural parts in automotive industry. Despite its outstanding properties like good castability, low density and nearly unlimited availability the negative aspects like weak corrosion and wear behaviour still limit the application of magnesium in industry [1]. So, the only economic solution is the deposition of a coating or a suitable surface treatment which provides both, wear and corrosion resistance. Today, plasma electrolytic anodisations are state of the art [2–5]. They provide acceptable corrosion resistance and protect the magnesium from mechanical damage due to their high hardness. On the other hand, their high porosity limits their use in combination with electrochemically noble materials, leading to galvanic corrosion [6]. In addition, the high surface roughness of the plasma electrolytic anodisations restricts their use in tribological applications, particularly under dry sliding conditions [7]. On the other hand, due to the high life time recommendations the application of magnesium in the automotive industries motion component field is a long term process. Nevertheless, there is a quite high industrial interest to apply magnesium in the motion component field in consumer applications like do‐it‐yourself or gardenig. Some examples are motor components of lawnmovers, motor saws or drills. Especially for these fields of application there are quite high demands on the corrosion properties due to undefined storage and the conditions during usage. In order to achieve smooth surfaces with high quality, the PVD technology moves into the centre of interest. Since the 1980s PVD coatings are well established and widely used for different industrial applications, mainly for steel and tool coatings. The authors were the first who carried out serious studies on the development of PVD coatings for magnesium alloys since 1999 [6, 7]. The extensive research activities lead to the recent development of a coating system, which provides both, good wear properties as well as good corrosion behaviour.