Intermetallic Particles Research Articles

Enhanced strength-ductility combination in the aluminum-gold system by heterogeneous distribution of nanoparticles via ultra-severe plastic deformation and reactive interdiffusion

Ultrafine-grained aluminum alloys are of interest due to their high strength-to-weight ratio, but they usually suffer from poor uniform ductility. In this study, an Al-Au alloy with a good combination of strength and ductility is produced by the heterogeneous distribution of Al2Au nanoparticles in an aluminum matrix. To generate such heterogeneity, the alloy is synthesized by ultra-severe plastic deformation of aluminum and gold powders via the high-pressure torsion (HPT) method. Reactive interdiffusion occurs during the process leading to the heterogeneous formation of intermetallic particles and a good strength-ductility synergy (200 MPa yield stress and 15% uniform elongation). Nanoparticles gradually distribute within the matrix and once a uniform nanoparticle distribution is achieved, the alloy shows no further increase in strength, but it completely loses its ductility. It is concluded that not only the presence of nanoparticles but more importantly the heterogeneity of their distribution can positively influence the strength-ductility combination in ultrafine-grained aluminum alloys. The findings of this study suggest that future studies on heterogeneous precipitation hardening can be a solution to achieve ductile precipitation-hardened alloys.

Impact of intermetallic phases on the localised pitting corrosion and high-temperature tensile strength of Al–Si[sbnd]Mg[sbnd]Cu[sbnd]Ni alloys

The influence of Ni-rich intermetallic particles (IMPs) on the microstructure, high-temperature mechanical properties, and corrosion behaviour of Al–Si–Mg–Cu–Ni alloys was investigated. The presence of coarse block-like γ-Al7Cu4Ni and thin needle-like δ-Al3NiCu IMPs contributed to low-temperature alloy strengthening during tensile tests. However, void nucleation and coalescence within the IMPs facilitated ductile fracture and alloy rupture, resulting in a lower tensile strength at high temperatures. Although both IMP phases had a cathodic electrochemical nature, resulting in strong galvanic corrosion, the γ-Al7Cu4Ni phase acted as the primary cathode, amplifying localised pitting while reducing the overall alloy corrosion resistance.

Parts repairing and microstructural refinement of high-pressure die cast aluminum alloys through friction stir processing for bulk production

A key challenge in the production of high-grade automotive aluminum components through the High-Pressure Die Casting (HPDC) process is the imperative to minimize imperfection. In addressing this concern, this study utilizes friction stir processing (FSP), a widely recognized intense plastic deformation technique. FSP is applied to systematically alter the microstructure of HPDC Al-4Mg-2Fe, a prominent alloy extensively used in the die-casting sector. By using the pass strategy to incorporate both one-pass and two-pass approaches, the microstructure is selectively altered to establish a defect-free processed zone. The utilization of FSP demonstrates its efficacy in breaking aluminum dendrites and acicular silicon particles, leading to a uniformly dispersed arrangement of equiaxed silicon particles within the aluminum-based matrix. In addition, FSP eradicates porosity and disintegrates needle-like Fe particles, resulting in a more refined and homogeneously distributed structure. Subsequently, the material's mechanical properties processed by FSP were assessed in the longitudinal direction concerning the processing axis and then compared with those of the original base material.The microstructural refinement and reduction in porosity induced by FSP result in a notable enhancement in hardness, with an increase of 23 % after one pass and 37 % after two passes. The substantial improvement in mechanical properties during the FSP process is predominantly attributed to modifications in the morphology, refinement, and dispersion of intermetallic particles within the matrix. This improvement is further complemented by the ultrafine dispersion of casting defects.This study underscores the efficacy of FSP as a valuable tool for modifying microstructures and improving mechanical properties in HPDC Al-4Mg-2Fe alloys. Such advancements align with the lightweighting objectives pursued by the automotive industry.

Optimization of chemistry and process parameters for control of intermetallic formation in Mg sludges

Intermetallic formation in sludge during magnesium (Mg) melting, holding and high pressure die casting practices is a very important issue. But, very often it is overlooked by academia, original equipment manufacturers (OEM), metal ingot producers and even die casters. The aim of this study was to minimize the intermetallic formation in Mg sludge via the optimization of the chemistry and process parameters. The Al8Mn5 intermetallic particles were identified by the microstructure analysis based on the Al and Mn ratio. The design of experiment (DOE) technique, Taguchi method, was employed to minimize the intermetallic formation in the sludge of Mg alloys with various chemical compositions of Al, Mn, Fe, and different process parameters, holding temperature and holding time. The sludge yield (SY) and intermetallic size (IS) was selected as two responses. The optimum combination of the levels in terms of minimizing the intermetallic formation were 9 wt.% Al, 0.15 wt.%Mn, 0.001 wt.% (10 ppm) Fe, 690 °C for the holding temperature and holding at 30 mins for the holding time, respectively. The best combination for smallest intermetallic size were 9 wt.% Al, 0.15 wt.%Mn, 0.001 wt.% (10 ppm) Fe, 630 °C for the holding temperature and holding at 60 mins for the holding time, respectively. Three groups of sludge factors, Chemical Sludge (CSF), Physical Sludge (PSF) and Comprehensive Sludge Factors (and CPSF) were established for prediction of sludge yields and intermetallic sizes in Al-containing Mg alloys. The CPSF with five independent variables including both chemical elements and process parameters gave high accuracy in prediction, as the prediction of the PSF with only the two processing parameters of the melt holding temperature and time showed a relatively large deviation from the experimental data. The Chemical Sludge Factor was primarily designed for small ingot producers and die casters with a limited melting and holding capacity, of which process parameters could be fixed easily. The Physical Sludge Factor could be used for mass production with a single type of Mg alloy, in which the chemistry fluctuation might be negligible. In large Mg casting suppliers with multiple melting and holding furnaces and a number of Mg alloys in production, the Comprehensive Sludge Factor should be implemented to diminish the sludge formation.

Investigation on Friction Stir Welding Parameters: Mechanical Properties, Correlations and Corrosion Behaviors of Aluminum/Titanium Dissimilar Welds

In industrial applications, welding of dissimilar metals such as aluminum (Al) and titanium (Ti) is a prerequisite for the development of hybrid components with improved mechanical and corrosion properties. However, dissimilar welding of the Al/Ti system is highly challenging due to differences in the physical and thermal properties of the two materials. In the present investigation, an attempt has been made to fabricate a dissimilar friction stir weld (FSW) of commercially pure Al and Ti and to elucidate the mechanism associated with superior joint formation. The process parameters, such as tool rotation speed, traverse speed and tool offset position have been optimized using Taguchi’s optimization technique. A detailed investigation of the weld with optimum process parameters has been carried out to reveal the mechanism of joint formation. The superior mechanical properties (24% higher ultimate tensile strength and 10% higher ductility than that of base Al) of the weld are attributed to the fabrication of a defect-free joint, formation of intercalated particles and an Al/Ti interlocking interface, homogeneous distribution of fine second-phase (Ti and/or intermetallics) particles in the weld nugget, reduction in the evolution of brittle Al3Ti intermetallic compounds (IMCs) and recrystallization and grain refinement of Al in the weld nugget. The potentio-dynamic polarization test indicated that the optimized Al/Ti weld has ~47% higher corrosion resistance than Al; it had a very mild corrosion attack due to the homogeneous dispersion of fine particles. The method and mechanism could have an immense influence on any dissimilar weld and metal matrix composites, improving their mechanical properties and corrosion resistance.

Cathodic protection of aluminium in seawater

AbstractCathodic protection of various 6000 aluminium alloys and variants of EN AW‐5083 in seawater has been studied. The alloys were immersed in seawater and polarized to about −1.06 V versus Ag/AgCl for 1 year. The cathodic current density increased initially due to formation of a copper film on the surface, but the effect was temporary. After 200 days, the current demand for cathodic protection had stabilized on all the investigated alloys at 0 to about 20 mA/m2, depending on the Fe/Si ratio in the alloy. Depending on the content of noble intermetallic particles, the aluminium will corrode at a low and constant rate. Application of a coating on the aluminium will decrease the cathodic current demand for cathodic protection significantly. Coatings on submerged aluminium are very stable and not susceptible to degradation mechanisms like cathodic disbonding.

Effect of the Fe/Mn Ratio on the Microstructural Evolution of the AA6063 Alloy with Homogenization Heat Treatment Interruption

The casting structure of the AA6063 alloy contains intermetallic particles of β-Al5FeSi, which can result in the fragility of the cast pieces. However, with heat treatment, the β phase transforms from a needle or plate form into an intermetallic phase known as α, which resembles Chinese-script in its morphology. To analyze the effect of the ratio of Fe/Mn with different ratios of 0.5, 0.75, and 1, a heat treatment process is used with intermittent interruptions. The alloy is subjected to a temperature of 575 °C for 12 h to determine the microstructural evolution of the β-Al6FeMn and α-Al15(FeMn)3Si2 phases. This study used scanning electron microscopy to conduct point analyses and elemental mappings of the intermetallics found in the casting and heat treatment samples. Additionally, X-ray diffraction was employed to determine the stoichiometry of the present phases. The results indicated that the cast structure contains β-Al6FeMn and α-Al15(FeMn)3Si2 phases and that the β-Al6FeMn phase transforms into the α-Al15(FeMn)3Si2 phase upon completion of the heat treatment process. By using specific Fe/Mn ratios, the formation of the needle-shaped Al5FeSi phase in the casting structure of the alloy can be inhibited, leading to the precipitation of phases such as β-Al6FeMn and α-Al15(FeMn)3Si2 instead.

Micro-adhesive wear and microhardness behavior of friction stir welded 2524-T3 aluminium alloy

Friction Stir Welding (FSW) emerges as a compelling solid-state welding technique for aluminium alloy components used as aircfrat materials. Despite being a solid-state process and mitigating numerous solidification challenges, it retains its thermomechanical nature, affecting the material's microstructure and, consequently, its mechanical properties. This concise communication sought to assess the impact of the FSW process on the micro-adhesive wear and microhardness properties of the 2524-T3 alloy. The results showed that the FSW process was executed successfully on 2524-T3 aluminium alloy plates as well as the great influence of intermetallic particles on hardness and micro-adhesive wear.

Formation of Li-Al LDH conversion layer on AA2024 alloy for corrosion protection

AA2024 aluminium alloy is widely used in the aerospace industry. However, it is known to be highly susceptible to localised corrosion, which is related to its complex microstructure, mainly the presence of numerous Cu-rich intermetallic particles. One of the effective solutions to increase their corrosion resistance relies on the formation of layered double hydroxide (LDH) based conversion coatings (CC). This investigation aims to understand how the conditions of in situ Li-Al LDH-CO32-/OH– CC growth affect their further protective ability. For that purpose, concentration of reactants (0.05–0.15 M Li2CO3), pH of the electrolyte (10–12), temperature (30–50 °C) and treatment time (15 min-30 h) were systematically varied. Additionally to that, NH4OH was applied as a chelating agent for the synthesis of Li-Al LDH-CO32-/OH– as well as for the pH control. The obtained protective coatings were evaluated by X-ray diffraction (XRD), scanning electron microscopy (SEM), glow discharge optical emission spectroscopy (GDOES), Raman spectroscopy, salt spray test (SST) and electrochemical impedance spectroscopy (EIS). Among all varied parameters, involvement of chelating agent was found to be the most efficient for the formation of a coating with the highest level of corrosion protection. This is attributed to the formation of soluble complexes between NH4OH and Cu, resulting in dissolution of the intermetallics. It also prevents further redeposition of Cu species and consequently, the formation of new highly active Cu cathodes on the AA2024 alloy surface.

Изучение влияния содержания гафния и эрбия на формирование микроструктуры при литье алюминиевого сплава 1590 в медный кокиль

Introduction. High-magnesium aluminum alloys are widely used in the automotive, building and aerospace industries due to its low specific gravity and high strength. The characteristics of such alloys can be improved by small additions of scandium and zirconium. However, scandium is very expensive, so in new generation alloys its amount is tended to be reduced. In the recently developed 1590 aluminum alloy, this was achieved by addition of erbium and hafnium. The objective of the paper is to study the effect of erbium and hafnium concentrations on the modification of the cast structure in 1590 aluminum alloy at high solidification rates. Research Methods. The paper investigates the microstructure, chemical composition and size of intermetallic compounds in specimens from ten alloy 1590 modifications with different hafnium and erbium contents cast into a copper chill mold with a solidification rate of 10 °C/sec. The grain structure was studied using an optical microscope. The chemical composition and size of the intermetallic phases were studied using a Tescan Vega 3 scanning electron microscope. Results and discussion. It is established that as the amount of hafnium and erbium increases, the cast structure is modified. In general, grain refinement with the addition of hafnium and erbium can be explained by a higher degree of supercooling between the solid and liquid phases. At a hafnium content of 0.16 %, the dendritic structure begins to transform into an equiaxed grain structure. This transformation can be explained by the appearance of primary intermetallic compounds of the Al3Sc type in the liquid phase. Such intermetallic compounds are identified at a concentration of erbium and hafnium equal to 0.16 %. Moreover, in all alloys eutectic intermetallic compounds are identified that contained manganese and iron and had no effect on the cast structure. Comparison with previously obtained results on the grain size of specimens cast into a steel mold shows that with higher solidification rate, the structure modification in 1590 alloy is getting less efficient. This is explained by an increase in the concentration of transition elements in the solid solution, primarily scandium, necessary for the formation of primary intermetallic particles.

Influence of nickel addition on the microstructure, mechanical, and wear properties of Zn‐40Al‐2Cu alloy

AbstractTo study the influence of nickel addition on the microstructure, mechanical and lubricated wear properties of Zn‐40Al‐2Cu alloy, one ternary and five quaternary Zn‐40Al‐2Cu‐(0.5‐2.5)Ni alloys were made by permanent mold casting. The wear behavior of these alloys was studied using a block‐on‐cylinder type test machine, after examining their microstructural and mechanical features. The microstructure of Zn‐40Al‐2Cu alloy was comprised of aluminum‐rich α dendrites and a eutectoid α+η phase mixture. The addition of nickel caused the formation of intermetallic Al3Ni particles in the microstructure of this alloy. As the nickel content of alloys increased their hardness, friction coefficient, working temperature, and average surface roughness increased to certain extents but their strength, ductility, impact resistance, and wear volume decreased. However, the values of their wear volume and average surface roughness exhibited opposite changes with increasing nickel content. The worn surfaces of Zn‐40Al‐2Cu‐Ni alloys were observed to be characterized by smearing and scratching marks. Furthermore, the wear and mechanical properties of these alloys were correlated, and the results were discussed in terms of their microstructural features. Finally, it may be concluded that the nickel addition adversely affects the ductility of Zn‐40Al‐2Cu alloy but increases its wear resistance.

Effect of Dispersing In Situ Al-Cu Intermetallic Compounds on Joint Strength in Friction Stir Welding of AA3003-H18 Sheets

In this study, friction stir welding (FSW) was employed to join AA3003-H18 sheets by incorporating in situ Al-Cu intermetallic compounds within the stir zone. The FSW process was carried out under three distinct conditions: (I) without applying powder, (II) by introducing Cu powder, and (III) by incorporating Cu-Al mixed powder (50 vol.% Cu, 50 vol.% Al). The powder was embedded into the gap between two sheets. Subsequently, two-pass FSW, involving both forward and backward movements, was conducted with a rotational speed of 1200 rpm and traverse speed of 100 mm/min across all three experimental conditions. In the second and third conditions, the formation of in situ intermetallic compounds occurred through a solid-state reaction between Cu particles and Al within the stir zone. Examination of the stir zone through optical and electron microscopic studies revealed that the utilization of Cu-Al mixed powder resulted in finer and more uniformly distributed Cu clusters and Al-Cu intermetallics than samples welded with Cu powder alone. Notably, the stir zone of samples incorporating Cu-Al mixed powder exhibited finely dispersed, completely gray Al-Cu intermetallic particles, whereas those with only Cu powder displayed predominantly coarse core-shell particles in the microstructure. The introduction of Cu-Al mixed powder during FSW resulted in a stir zone with an average hardness of 74 HB, showing a 14% increase compared to the cases where Cu powder alone was added (65 HB). Tensile tests, conducted in both transverse and longitudinal directions on the FSWed samples, did not exhibit a consistent trend across the three mentioned conditions. Transverse tensile strength consistently ranged between 107 and 110 MPa, with joint efficiency varying from 52% to 54%. However, the longitudinal tensile strength of the joint with added Cu-Al mixed powder (158 MPa) surpassed those welded with Cu powder alone (134 MPa).

The effect of hexafluorozirconic acid concentration on the formation and corrosion resistance of trivalent chromium conversion coatings on AlSi12Cu1(Fe) cast alloy

AlSi12Cu1(Fe) alloy was subjected to the conversion bath containing: Cr2(SO4)3, HF and 200–800 ppm Zr (as H2ZrF6). Coatings composed mostly of ZrO2 and to a smaller extent by Cr(OH)3 with granular morphology were obtained. Concentration of Zr in the conversion bath did not affect the coatings thickness, which was non-uniform and ranged from 35 to 90 nm. Cracking and detachment were observed, which are due to the presence of possible phases like: Si, Cu0.01Al0.97Si0.02, FeAl3Si2 and Al2Cu, except the α–Al phase. These Cu- and Fe-rich intermetallic particles serve as the cathodic areas that are responsible for the formation of micrometric sizes numerous spheroids in the coating due to intensive hydrogen evolution. Longer protective effect, up to 240 hrs in a neutral salt spray and the lowest corrosion currents after 5 days in 0.05 M NaCl were obtained at 600 and 800 ppm Zr in the bath, respectively. It was due to higher content of oxidized chromium and aluminum compounds in these TCC coatings.

Superior hydrogen production rate by corrosion of recycled aluminum alloys: Feeding a PEM fuel cell

Aluminum is one of the most versatile materials for the dynamic global economy due to its mechanical properties, recyclability, and lightweight. The production of hydrogen from aluminum via hydrolysis in alkaline media offers another advantage of it. Recycling the post-consumer aluminum scraps leads to the formation of some undesirable intermetallic particles which are not only detrimental to mechanical properties but also to repeated recycling. In this study, the hydrolysis performance of a recycled aluminum alloy was compared with that of the primarily produced one. The results showed that the Mg solutes at the grain boundaries (GBs), Fe-containing and Mg2Si particles, stress concentration around the GBs, and thickness of the passive layer can affect the hydrogen generation rate of the specimens. The specimens were also tested in a proton-exchange membrane fuel cell to evaluate their hydrogen generation performance. The recycled aluminum alloy that can increase the hydrogen yield significantly increases the power of PEMFC.

Effect of delayed inhibitor supply on AA2024-T3 intermetallic activity: A local in situ analysis with reflected microscopy

Understanding how late an inhibitor can be released once corrosion initiated without compromising corrosion protection may help in developing more efficient anticorrosion coatings. We explored this idea through time-controlled Ce(NO3)3 availability to AA2024-T3 immersed in 0.05 M NaCl. Ce(NO3)3 was supplied at 0, 30, 60, and 180 s from the start of immersion to get a concentration of 0.001 M. Detailed visualization of surface changes at the intermetallic particle level was obtained using in-situ reflected microscopy. SEM-EDX and confocal laser microscopy confirmed the extent of intermetallic degradation and local inhibitor deposition corresponding to operando changes. When the inhibitor is supplied within 60 s of immersion, the surface changes slowdown earlier and are visually less extensive than in uninhibited systems. Furthermore, our results highlight the potential of reflected microscopy for local corrosion inhibition studies and underscore the importance of understanding the interaction between inhibitor release timing and corrosion protection.

Microstructure, Hardness and Corrosion Resistance of Al-TiC MMC Prepared by Laser Cladding on AZ31B Magnesium Alloy

Magnesium alloy is extensively used in aircraft, automobiles, and electronic industries due to its low density, high specific strength, and enhanced machinability. However, low hardness and poor corrosion resistance limit its application. In this work, an Al-TiC metal matrix composite (MMC) was prepared on AZ31B magnesium alloy via laser cladding. The effects of laser power and TiC content on the microstructure, hardness, and corrosion resistance of the MMC were investigated. The results showed that the MMC with 10% TiC had a hardness of 184 HV0.1, which was 3.5 times higher than 52 HV0.1 of the substrate. The current density of MMC with 10% TiC was 3.90 × 10−7 A/cm2, which was three orders of magnitude lower than 5.45 × 10−4 A/cm2 of the substrate. Due to more intermetallic compounds (IMCs) and TiC particles, the MMC with 30% TiC had higher hardness. The increased laser power would not change the phase composition, but it contributed to the formation of a concave crescent shape, promoted the diffusion of Mg, and induced the formation of a thicker Al3Mg2 transition layer. Modifications in the TiC concentration markedly influenced the coating’s microstructural characteristics.

Intermetallic and dispersoid structures in AA3104 aluminium alloy during two-step homogenisation

During homogenisation of the AA3104 cast ingot, a phase transformation of intermetallic particles from β-Al6(Fe,Mn) orthorhombic phase to harder α-Alx(Fe,Mn)3Si2 cubic phase occurs. The large constituent intermetallic particles, regardless of phase, assist in the recrystallisation nucleation process through particle stimulated nucleation (PSN). Ultimately, this helps to refine grain size. The sub-micron dispersoids act to impede grain boundary migration through a Zener drag mechanism. For this reason, the dispersoids that form during homogenisation are critical to the recrystallisation kinetics during subsequent rolling, with smaller dispersoids being better suited to instances where the minimisation of recrystallisation is required during hot rolling. This work simulates an industrial two-step homogenisation practice with variations in the peak temperature of the first step between 560 °C and 580 °C. The effect of this temperature variation on the intermetallic particle phase evolution is investigated. The aim is to identify the ideal intermetallic phase balance and the dispersoid structure that are best suited for the minimisation of recrystallisation during hot rolling through maximising Zener drag and maintaining galling resistance. The results indicate a trend where an increase in homogenisation temperature from 560 °C to 580 °C yields, firstly, an increase in the volume fraction of the α-phase particles to greater than 50% of the total volume fraction at both the edge and the centre of the ingot and, secondly, it yields an increased dispersoid size. Thus, a lower temperature homogenisation practice produces a near-ideal combination of intermetallic particle phase distribution, as well as dispersoid size, which is critical for Zener drag and the minimization of recrystallisation during the hot rolling processes.

Deposition of NiAl/Al3Ni2(CrB2) Coatings from Ni, Al and CrB2 Powders Using Mechanical Synthesis in Planetary Ball Mill.

Interest in composite thick coatings with an intermetallic matrix stimulates the development of new deposition techniques like the co-milling of pre-alloyed NiAl powder with platelet-shaped substrates. Obtained coatings were up to several micrometers thick as cold-welding of intermetallic particles was effective only at the start of this process, while later, chipping prevailed over added material. The present experiment covered the co-milling in the planetary ball mill of Ni and Al elemental powders (1:1 molar ratio) with AISI 304 steel platelets for 32 h at 300 rpm. Next, this process was repeated with an admixture of 15 wt.% of CrB2 powder. In both cases, their milling succeeded in producing up to a 200 μm coating after 4 h. The use of light, scanning and transmission electron microscopy (LM/SEM/TEM) helped to establish that the coatings had gradient microstructures with more refined crystallites of NiAl, Al3Ni2 and CrB2 closer to the surface. With the addition of a ceramic phase, the coatings presented higher hardness and lower friction during dry wear tests both at RT and at 500 °C.

Electrochemical Evaluation of Al-5 wt% Zn Metal-Rich Primer for Protection of Al-Zn-Mg-Cu Alloy in NaCl

An intact and X-scribed Al-5wt%Zn-rich primer (AlRP) without pretreatment or topcoat was evaluated for its ability to suppress potential-dependent intergranular corrosion and intergranular stress corrosion cracking of peak-aged AA7075A-T651 in NaCl salt fog and full immersion. The ability of the primer to provide sacrificial anode-based cathodic prevention of peak-aged AA7075-T651 substrate was evaluated both under the primer coating and at scratches. The AlRP evaluated consisted an epoxy-based resin embedded with spherical Al-5wt%Zn pigment particles. Performance was evaluated under full immersion in 0.6 M NaCl solution and compared to ASTM B117 salt spray exposure using two approaches. These consisted of the University of Virginia (UVA) cycle test on intact coatings and the full immersion galvanic couple testing on simulated scratched panels created when intact coatings form bimetal couples with bare AA7075-T651. Focus was placed on the ability of the AlRP to achieve a targeted intermediate galvanic couple potential near a “prevention” potential which suppresses stress corrosion crack growth, intermetallic particle corrosion as well as intergranular corrosion. The long-term (24-h) open-circuit potential (OCP) of AlRP-coated AA7075-T651 in 0.6 M NaCl indicated that the AlRP provided less than 100 mV of cathodic potential shift of the intact coating from its OCP in 0.6 M NaCl. Electrochemical cycle testing conducted at a potentiostatic hold of –0.95 VSCE demonstrates that the AlRP did not enable sacrificial anode-based cathodic protection as the coupled potential remained at the corrosion potential of bare AA7075-T651. Furthermore, the current observed throughout galvanic corrosion experiments coupling of AlRP to AA7075-T651 indicated the AlRP coating was a cathode in the bimetal galvanic couple. ASTM B117 salt spray exposure of the AlRP revealed oxidation of the AA7075-T651 substrate below the primer detected as a continually growing oxygen signal at the primer-substrate interface that did not arrest corrosion over the exposure period.

Effect of Microstructure on Corrosion Behavior of Cold Sprayed Aluminum Alloy 5083

This paper investigates the effect of the microstructure on the corrosion behavior of cold sprayed (CS) AA5083 compared to its wrought counterpart. It has been shown that the microstructure of CS aluminum alloys, such as AA2024, AA6061, and AA7075, affects their corrosion behavior; however, investigations of the corrosion behavior of CS AA5083 with a direct comparison to wrought AA5083 have been limited. The microstructure and corrosion behavior of CS AA5083 were examined by scanning electron microscopy (SEM), transmission electron microscopy (TEM), energy dispersive X-ray spectroscopy (EDS), electron backscattered diffraction (EBSD), electrochemical and immersion tests, and ASTM G67. The CS process resulted in microstructural changes, such as the size and spatial distribution of intermetallic particles, grain size, and misorientation. The refined grain size and intermetallic particles along prior particle boundaries stimulated the initiation and propagation of localized corrosion. Electrochemical tests presented enhanced anodic kinetics with high pitting susceptibility, giving rise to extensive localized corrosion in CS AA5083. The ASTM G67 test demonstrated significantly higher mass loss for CS AA5083 compared to its wrought counterpart due to preferential attack within prior particle boundary regions in the CS microstructure. Possible mechanisms of intergranular corrosion (IGC) propagation at prior particle boundary regions have been discussed.