Simultaneously enhancing mechanical and anti-corrosion properties of aluminum through electrodeposition of supersaturated Al(Fe) solid solutions

Abstract

The heterogeneous microstructure in bulk aluminum (Al) alloys or coatings, comprising an α-Al solid solution matrix and coarse intermetallic compounds (IMCs), poses a challenge in balancing mechanical and anti-corrosion properties. This challenge is particularly pronounced in Al alloys with high iron (Fe) content. Here, supersaturated Al(Fe) solid solutions with a single phase have been electrodeposited using imidazolium chloroaluminate ionic liquids (ILs). Ferrous chloride (FeCl2) dissolved in Lewis-acidic ILs is assumed to form Cl-bridged [Fe(AlCl4)4]2−, which, together with the well-known Al2Cl7− species, supports the reduction and deposition of Al(Fe) alloy coatings. The supersaturated Fe solutes significantly strengthens the Al matrix, with the hardness of Al(Fe, 6.6 at.%) reaching up to 3.43 GPa, surpassing that of any commercial Al alloys and other binary Al-based solid solutions. Moreover, the Al(Fe) deposits demonstrate superior anti-corrosion performance compared to pure Al. The homogeneous microstructure and extended Fe solubility within Al(Fe) solid solutions inherently contributes to a simultaneous improvements in mechanical and anti-corrosion properties. The nanograined and compact structure also benefit these properties. Accordingly, the combination of electrodeposition techniques and Al(Fe) alloys offers a promising approach for providing effective mechanical and chemical protection on metal surfaces.