Abstract
In the present research work, the effect of shoulder diameter on the corrosion rate of stir zones (SZs) of dissimilar joints exposed to 3.5 M NaCl solution fabricated via friction stir welding (FSW) was studied in detail. In FSW, the tool shoulder diameter as one of the important process parameters significantly affects frictional heat input and material flow leading to the heterogeneous distribution of second phase particles (precipitates) that alters the electrochemical behaviour of FSWed joints. The influence of shoulder diameter on corrosion rate was analyzed via macro and microstructural characterization and open circuit potentiodynamic testing. The surface morphology and microstructural analysis of specimens reveal the occurrence of both pitting and intergranular corrosion (IGC) in base materials and SZs of welded specimens. Among the welded specimens, the SZ of weld I fabricated under shoulder size of 18 mm revealed the lower corrosion resistance. The potentiodynamic test revealed that weld I having very fine grains as compared to other joints exhibits the highest current density and corrosion rate.
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