Galvanic and Local Corrosion of Aluminum Alloy 6061-T6 Coupled to Non-Passivating and Passivating Alloys

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Marine and aerospace structures sometimes combine lightweight aluminum alloys with dissimilar metals to optimize mechanical performance and reduce costs. Unfortunately, the exposure of such dissimilar couples in a harsh environment can cause severe corrosion damage to the aluminum structure due to its position in the galvanic series. Corrosion of Aluminum Alloy (AA) 6061-T6 coupled to non-passivating and passivating alloys was studied to elucidate galvanic effects on local corrosion. In this work, local and galvanic corrosion were quantified, the effects of cathode material on local electrolyte pH were explored, and a relationship between pH and local-corrosion of AA6061-T6 was established.Experimental studies quantified local and galvanic corrosion of AA6061-T6 coupled to 316 stainless steel, copper, titanium alloy Ti6Al4V, and 316 stainless steel coated with titanium nitride, chromium nitride, and a sol-gel nano-coating. Galvanic couples were misted with 3.15 wt.% sodium chloride solution and exposed in a controlled temperature-humidity chamber. Galvanic currents were measured during exposure, and the total mass loss of the aluminum alloy was determined to quantify the corrosion damage. Exposure tests showed that galvanic corrosion decreases over time and accounts for less than 15% of the total corrosion of AA6061-T6. Therefore, most aluminum corrosion damage was caused by local corrosion. In addition, immersion experiments of AA6061-T6 galvanic couples in gelled 3.15 wt.% NaCl solutions showed that galvanic coupling influences the evolution of electrolyte pH leading to severe acidification at the aluminum anode surface and alkalization around the cathode. The solution pH at the aluminum surface was decreased by galvanic action and severity of pH decrease depends on galvanic couple materials and design. To quantify the effect of acidity on local corrosion of AA6061-T6, potentiodynamic polarization tests were performed in aerated and deaerated 3.15 wt.% NaCl solution adjusted to different pH values. Anodic dissolution reactions and cathodic oxygen reduction reactions show significantly higher anodic and cathodic currents for more acidic solutions due to the instability of the passive oxide film of aluminum. This film is stable in near-neutral solutions and unstable in highly acidic solutions. As a result, the breakdown of the passive film increases the effective area contributing to anodic or cathodic currents resulting in enhanced local corrosion.The series of experimental results show that galvanic interaction leads to a decrease of pH at the aluminum anode, and therefore increasing local corrosion of the aluminum surface. The increase of local corrosion induced in a galvanic couple depends on the cathode material and underlines the importance of accounting for local corrosion and pH-dependent corrosion kinetics when predicting the galvanic compatibility of aluminum alloys.