Exfoliation Corrosion Test Research Articles

Corrosion damage evolution of the aircraft aluminum alloy 2024 T3

Purpose – The purpose of this paper is to quantify the corrosion damage evolution that has occurred on the aircraft aluminum alloy 2024 after the exposure to Exfoliation Corrosion Test (EXCO) solution. Moreover, the effect of the evolving corrosion damage on the materials mechanical properties has been assessed. The relevance of the corrosion damage induced by the exposure to the laboratory EXCO for linking it to the damage developed after the exposure of the material on several outdoor corrosive environments or in service is discussed. Design/methodology/approach – To induce corrosion damage the EXCO has been used. For the quantification of corrosion damage the metallographic features considered have been pit depth, diameter, pitting density and pit shape. The effect of the evolving corrosion damage on the materials mechanical properties has been assessed by means of tensile tests on pre corroded specimens. Findings – The results have shown that corrosion damage starts from pitting and evolves to exfoliation, after the development of intergranular corrosion. This evolution is expressed by the increase of the depth of attack, as well as through the significant growth of the diameter of the damaged areas. The results of the tensile tests performed on pre corroded material made an appreciable decrease of the materials tensile properties evident. The decrease of the tensile ductility may become dramatic and increases on severity with increasing corrosion exposure time. SEM fractography revealed a quasi-cleavage zone beneath the depth of corrosion attack. Originality/value – The results underline the impact of corrosion damage on the mechanical behavior of the aluminum alloy 2024 T3 and demonstrate the need for further investigation of the corrosion effect on the structural integrity of the material. This work provides an experimental database concerning the quantification of corrosion damage evolution and the loss of material properties due to corrosion.

Regulation Mechanism of Novel Thermomechanical Treatment on Microstructure and Properties in Al-Zn-Mg-Cu Alloy

Scanning electron microscopy, transmission electron microscopy, tensile test, exfoliation corrosion test, and slow strain rate tensile test were applied to investigate the properties and microstructure of Al-Zn-Mg-Cu alloy processed by final thermomechanical treatment, retrogression reaging, and novel thermomechanical treatment (a combination of retrogression reaging with cold or warm rolling). The results indicate that in comparison with conventional heat treatment, the novel thermomechanical treatment reduces the stress corrosion susceptibility. A good combination of mechanical properties, stress corrosion resistance, and exfoliation corrosion resistance can be obtained by combining retrogression reaging with warm rolling. The mechanism of the novel thermomechanical treatment is the synergistic effect of composite microstructure such as grain morphology, dislocation substructures, as well as the morphology and distribution of primary phases and precipitations.

Influence of grain structure on quench sensitivity relative to localized corrosion of high strength aluminum alloy

The influence of grain structure on quench sensitivity relative to localized corrosion of high strength aluminum alloy 7055 was investigated by electrochemical test, accelerated exfoliation corrosion test, optical microscopy (OM), scanning electron microscopy (SEM), transmission electron microscopy (TEM) and scanning transmission electron microscopy (STEM). The decrease of quench rate led to lower corrosion resistance of both the homogenized and solution heat treated (HS) alloy with equiaxed grains and the hot-rolled and solution heat treated (HRS) alloy with elongated grains, but there was a higher increment in corrosion depth and corrosion current density and a higher decrement in corrosion potential for the latter alloy, which therefore exhibited higher quench sensitivity. It is because in this alloy the larger amount of (sub) grain boundaries led to a higher increment in the amount of quench-induced η phase and precipitates free zone at (sub) grain boundaries with the decrease of quench rate, and there was a larger increment in the content of Zn, Mg and Cu in the η phase at grain boundaries due to slow quenching. The presence of subgrain boundaries in the HRS alloy tended to increase corrosion resistance at high quench rates higher than about 630 °C/min but decrease it at lower quench rates.

Mechanical properties and corrosion resistance of Al–Cu–Mg–Ag heat-resistant alloy modified by interrupted aging

Abstract The effects of interrupted aging on the microstructure, mechanical properties and corrosion resistance of Al–Cu–Mg–Ag heat-resistant alloy were investigated by hardness tests, tensile tests, exfoliation corrosion (EXCO) tests, transmission electron microscopy (TEM) and electrochemical analysis. Results showed some phases precipitated during the interrupted aging process in Al–Cu–Mg–Ag alloy, which were called secondary precipitations. The precipitations both in the grains and the grain boundaries were refined by interrupted aging. The phases on the grain boundaries of the single-aged sample were distributed discontinuously, whereas those of the interrupted-aged sample were chain-like with a wider precipitation free zone (PFZ) on both sides of the grain boundary. The elongation of Al–Cu–Mg–Ag alloy increased by 37.7% while the tensile and yield strength slightly decreased after interrupted aging. The corrosion resistance of Al–Cu–Mg–Ag alloy was mainly determined by the PFZ with the lowest self-corrosion potential. The coarse and discontinuously distributed precipitations on the grain boundaries of the single-aged sample gave rise to larger efficient PFZ width than that of the interrupted-aged sample, which then lead to wider corrosion passageway and resulted in the better exfoliation corrosion resistance of Al–Cu–Mg–Ag alloy treated by interrupted aging.

Corrosion Performance of Newly Developed Al-Mg Alloys

The corrosion behavior of the newly developed Al-Mg alloys was investigated in terms of their alloying element and thermo-mechanical treatments by means of intergranular corrosion test, exfoliation corrosion test, scanning electron microscopy and transmission electron microscopy. The results show that, with the increase of Mg content the mass loss of the alloys in concentrated nitric acid increased, correspondingly their intergranular corrosion resistance decreases. Zn addition to the Al-Mg alloys led to the formation of Mg32(Al, Zn)49phase at the grain boundary, which dramatically increased the intergranular corrosion resistance of the alloys. The corrosion resistance of the alloys was also modified by thermo- mechanical treatment. Both intergranular corrosion resistance and exfoliation corrosion resistance of the alloys were dramatically increased by a proper post stabilizing treatment after cold rolling reduction. The residual stress, higher dislocation density and morphology of elongated grains after cold rolling reduction can lead to more continuous precipitation at the grain boundary, thus decrease the corrosion resistance of the alloys.

Numerical simulation of tensile behavior of corroded aluminum alloy 2024 T3

Purpose – The purpose of this paper is to develop a multi-scale modeling approach for simulating the tensile behavior of corroded aluminum alloy 2024 T3. Design/methodology/approach – The approach combines two FE models: a model of a three-dimensional representative unit cell representing a pit and a model of the tensile specimen. The models lie at the micro- and macro-scales, respectively. The local homogenized mechanical behavior of the corroded material is simulated for different pit configurations. Then, the behavior of the pits is introduced into different areas (elements) of the tensile specimen and final analyses are performed to simulate the mechanical behavior of the corroded material. The approach has been applied to six different exposure periods of the exfoliation corrosion test. Findings – The numerical results show that the presence of pits and exfoliated areas reduces the yield strength of the material. The comparison of predicted elongation to fracture with the experimental of each exposure period value allows for the indirect assessment of the effect of hydrogen embrittlement. Originality/value – Since the characteristics of corrosion damage evolution with exposure time are constant for the specific material, the model could be applied for the simulation of the mechanical behavior of any corroded structural part (e.g. a mechanically fastened panel) made from the aluminum 2024 T3 alloy.

Exfoliation corrosion behavior of 7050-T6 aluminum alloy treated with various quench transfer time

The exfoliation corrosion (EFC) behavior of 7050-T6 aluminum alloy treated with various quench transfer time after solution heat treatment was investigated by standard EFC immersion tests, strength loss measurements after EFC tests and electrochemical impedance spectroscope (EIS) technique. The results showed that EFC resistance of the alloy decreased with increasing quench transfer time. Backscattered electron scanning electron microscope (SEM) together with transmission electron microscope (TEM) observations revealed that the coverage ratio and microstructure of precipitates at grain boundary area are the most important factors which influence the EFC susceptibility of the alloy, while precipitate-free zone (PFZ) near grain boundary has no or only a minor effect on it. In addition, galvanostatic measurements of the alloy present a good correlation between EFC resistance and transients in potential. The cumulated number of transients in potential can be used to evaluate EFC resistance of the alloy.

Effect of Scandium Addition on Mechanical Properties and Corrosion Resistance of Medium Strength Al-Zn-Mg-Cu) Alloy

Al-Zn-Mg alloys are widely used construct material for wide range of application including automotive industry, building, and aviation. Scandium is rare earth metal, which modifies structure of semi-products and can lead to increasing of tensile and yield strength because of Al3Sc intermetallics of nanoscale size. This paper describes results of influence of small addition of scandium (0,08 wt. %) on mechanical and corrosion properties of cold-rolled sheets of 1913 alloy. 1913 is Russian medium strength corrosion resistant weldable Al-Zn-Mg alloy with addition of Cu for improvement of stress corrosion resistance and Mn with Zr for structure improvement. It is shown that addition of Sc transforms kinetics of artificial aging and accelerates decomposition of solid solution, besides tensile strength increases up to 50 MPa in artificially aged tempers. Changes in microstructure and quench sensitivity are described; results of intergranural corrosion, exfoliation and stress corrosion tests are introduced after different heat treatment including peak strength aging and overaging tempers.

Influence of various aging treatments on microstructure, strength and corrosion behaviour of high Zn content Al–Zn–Mg–Cu alloy

In this paper, the influence of T6, T74 and RRA aging treatments on microstructure, strength and corrosion behaviour of high Zn content Al–Zn–Mg–Cu alloy was investigated by tensile properties tests, inter-granular corrosion (IGC) tests, exfoliation corrosion (EXCO) tests, polarisation tests, metallographic microscope and transmission electron microscopy (TEM) analysis. The results show that the T74 and RRA temper can increase the size and the distribution discontinuity of the grain boundaries precipitates (GBPs), thus leading to improvement of the corrosion resistance. However, with the coarser matrix precipitates (MPs) relative to T6 treatment, RRA and T74 temper both have a decrease in strength. Besides, all the performances (including mechanical properties and corrosion properties) of the RRA treatment show an intermediate level relative to T6 and T74. Therefore, we can select the appropriate heat treatment process according to the different performance requirements in the industrial production.

Influence of aging temperature on corrosion behavior of Al–Zn–Mg–Sc–Zr alloy

Al–Zn–Mg–Sc–Zr alloy sheets were prepared using water chilling copper mould ingot metallurgy processing which was protected by active flux. The effect of aging temperature on the corrosion characteristics of Al–Zn–Mg–Sc–Zr alloy was investigated by means of exfoliation corrosion testing, potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) combined with transmission electron microscopy, scanning electron microscopy and optical microscopy observation. It is found that with increasing the aging temperature the susceptibility to exfoliation corrosion decreases. Electrochemical measurements reveal that at early stage of immersion in testing solution, EIS plots of the samples are composed of a capacitive arc and an inductive loop. Inductive loop disappears with the increasing of immersion time and two time constants in impedance diagrams appear. Moreover, the trends of corrosion resistance are further confirmed by polarization curve and EIS test. In addition, transmission electron microscopy observations show that the improved corrosion resistance from increasing aging temperature is duo to the coarsening of matrix and separated precipitates at the grain boundary, and the increased spacing of grain boundary precipitates.

The effect of quench transfer time on microstructure and localized corrosion behavior of 7050‐T6 Al alloy

The microstructure and localized corrosion behavior of the 7050‐T6 Al alloys treated with different quench transfer time were investigated. Optical microscope observations show that the volume fraction of the recrystallized grains increases slightly with prolonging quench transfer time. Scanning electron microscope observations reveal that the stable η (MgZn2) phase nucleates and precipitates on grain boundaries in the process of transferring to quench. Further observations, using transmission electron microscope, found that the size, nearest neighbor distance, and copper content of the grain‐boundary precipitates increase with quench delay. As a result, the open‐circuit potentials and charge transfer resistance (Rt) of the alloys reduce with increasing transfer time, while the susceptibility to intergranular corrosion (IGC) and strength loss after exfoliation corrosion tests increase sharply. In addition, the IGC network appearance changes from large network to fine network structure, due to the different temperature range where very rapid η phase precipitation takes place between on grain boundaries and on sub‐grain boundaries.

Effect of Aging Treatments on Microstructure and Exfoliation Corrosion Behavior of Spray Forming 7075 Alloy

Mechanical properties, microstructure and exfoliation corrosion (EXCO) behavior of spraying forming 7075 alloy underwent retrogression and re-aging (RRA) were studied by tensile test, transmission electron microscopy and EXCO test, and compared with those of T6 peak aging and T73 overaging treatments. The results show that after T6 treatment, abundance transgranular dispersive η phases make tensile strength of the alloy reach 760MPa, elongation and EXCO rating are only 4.8% and ED respectively by dint of continuous η phases at grain boundaries and narrow precipitate free zones (PFZ). After T73 treatment, interrupted η phases at grain boundaries and wide PFZ can improve elongation and EXCO resistance, but depressed volume fraction of coarsening transgranular η phases reduce tensile strength to 676MPa. After RRA treatment (120°C/24h + 200°C/10min + 120°C/24h), abundance transgranular dispersive η phases separate out again, η phases at grain boundaries interrupt, and PFZ widen slightly. Tensile strength, elongation and EXCO rating of alloy are 758MPa, 8.4% and EA respectively.

Effect of aging on corrosion property, electrochemical behavior and microstructure of AlZnMgCu alloy

The effect of aging treatment on corrosion behavior of AlZnMgCu alloy was investigated by means of intergranular corrosion test, exfoliation corrosion test, electrochemical analysis, and transmission electron microscope. The results show that intergranular and exfoliation corrosion susceptibility of the studied alloy decrease gradually with increasing aging time. This is further confirmed by potentiodynamic polarization and electrochemical impedance spectroscopy tests, which show the corrosion resistance increased and corrosion density decreased with prolonging aging time. Moreover, the variation of impedance parameters simulated in terms of an equivalent electrical circuit present better reflection to the corrosion process, thus give valuable information to evaluate the corrosion property. According to microstructural observation, the morphology and distribution of grain boundary precipitate varied with aging treatment have decisive influence to the corrosion behavior.

Influence of dual retrogression and re-aging temper on microstructure, strength and exfoliation corrosion behavior of Al–Zn–Mg–Cu alloy

Influence of dual retrogression and re-aging (dual-RRA) temper on microstructure, strength and exfoliation corrosion (EC) behavior of Al–Zn–Mg–Cu alloy was investigated by hardness measurements, tensile properties tests, exfoliation corrosion tests, transmission electron microscopy (TEM) and scanning electron microscopy (SEM) observation combined energy dispersive X-ray detector (EDX) analysis. Dual-RRA temper maintains the matrix precipitates (MPs) similar to RRA temper, meanwhile obtains∼coarser and sparser grain boundary precipitates (GBPs) as well as higher∼Cu and lower Zn content compared with T76 temper. Therefore, dual-RRA temper not only keeps strength equivalent to the RRA temper but also obtains higher EC resistance than T76 temper.

A critical consideration for the use of Al-cladding for protecting aircraft aluminum alloy 2024 against corrosion

The necessity of involving Al cladding as a means of protecting the aircraft aluminum alloy 2024 against corrosion has been assessed experimentally. Bare as well as Al-clad protected 2024 specimens were pre-corroded and then subjected to mechanical tests. By recognizing the lack on validated concepts for the laboratory simulation of the corrosion damage expected in the service conditions of an aircraft structure, in the present work two different laboratory corrosion tests, namely the immersion of the alloy in a 3.5% NaCl solution, and the exfoliation corrosion test have been employed for pre-corroding the specimens. For the case of the aggressive exfoliation corrosion environment the protective role of Al-cladding is essential for ensuring the good tensile and fatigue behavior of the 2024 alloy. On the other hand, the results have shown that for the case of the mild 3.5% NaCl solution environment, the use of a cladding layer downgrades the fatigue behavior of the material, thus giving raise to doubt on the need of involving cladding. The results demonstrate the need for systematic efforts for the development of concepts which will allow the laboratory simulation of corrosion accumulated in service.

Effect of heat treatment on strength, exfoliation corrosion and electrochemical behavior of 7085 aluminum alloy

The influence of heat treatment on strength, exfoliation corrosion and electrochemical behavior of 7085 aluminum alloy has been investigated by tensile testing, exfoliation corrosion testing, polarization curve and electrochemical impedance spectroscopy (EIS) combined with transmission electron microscope (TEM). The results show that retrogression and reaging (RRA) improved exfoliation corrosion resistance without sacrificing the strength compared to T6 temper. Dual-retrogression and reaging (DRRA) improved exfoliation corrosion resistance equivalent to T74 temper and maintained the strength similar to retrogression and reaging. The high-temperature and the subsequent low-temperature aging (HLA) decreased the strength and corrosion resistance compared to the T6 temper. The trends of corrosion resistance are further confirmed by polarization curve experiment and EIS test. The effect of heat treatment on strength and corrosion resistance is explained by the role of matrix precipitates and grain boundary precipitates, respectively.

Corrosion behaviour of weld heat affected zone of aluminium alloy 7075

The microstructure of the weld heat affected zone (HAZ) of alloy 7075 was simulated using a Gleeble system. The corrosion behaviour of several locations in the weld HAZ was investigated by means of differential scanning calorimetry, electrochemical measurement in 3·5 wt-%NaCl solution, and exfoliation corrosion tests. Different exfoliation corrosion morphologies for the base metal and weld HAZ were also observed. The corrosion morphology of the weld HAZ was mainly related to the degree of precipitation of η' phase in the matrix. The HAZ in the region of the peak temperature 377° C contained the most precipitation of η phase, but no effect on corrosion morphology as a result of T6 post-weld heat treatment was observed.

Exfoliation corrosion testing of aluminium alloys

Exfoliation corrosion testing of aluminium alloys

Exfoliation corrosion testing of aluminium alloys

Abstract The exfoliation corrosion behaviour of sheet and plate materials of various conventional aluminium and Al–Li alloys has been evaluated using accelerated tests. Results are .compared with atmospheric exposure data published in the literature to assess the applicability of the testing techniques employed. For damage tolerant Al–Li based sheet and plate, the cyclic acidified salt fog (Mastmaasis) test according to ASTM G85, Annex A2 indicated susceptibility to exfoliation corrosion, reproducing the limited outdoor corrosion data for the Al–Li alloys 8090–T81 and 2091–T84 as well as marine exposure results reported for the conventional alloys 2024–T351 and 7075–T7351. Therefore, it appears to be a promising testing technique for predicting the service performance of high strength aluminium alloys. Compared with the ratings determined following the cyclic acidified saltfog tests, the standard Exco test according to ASTM G34 indicated better exfoliation corrosion behaviour of the alloys investigated, e...

Change in structure and properties in stepped aging of V95 aluminum alloy plates

1. Stepped aging of V95 alloy, leading to a decrease in the yield strength of not less than 9–12% (T2 condition) and 15–20% (T3 condition) in comparison with the T1 condition, provides a change in the investigated corrosion characteristics by not less than ∼85 and 100%, respectively, of the possible change in these properties. 2. A decrease in the hardening rate within the investigated limits leads to a decrease in the maximum of the tensile and yield strengths by 20–30 MPa and makes it possible to reduce the aging time until reaching the maximum in these characteristics by ∼2 h. In addition, the strength characteristics in overaging, the investigated corrosion characteristics, and the electrical resistance do not change but the character of precipitates in aging does changes. 3. With an increase in aging time the corrosion character in intergranular corrosion and exfoliation corrosion tests changes from preferential damage of the boundaries elongated in the rolling direction to damage of the majority of the fragment boundaries. This is caused by equalization of the intensity of decomposition in the boundaries of different types in overaging.