Electrochemical corrosion behaviour of stir zone of friction stir welded dissimilar joints of AA6061 aluminium-AZ31B magnesium alloys

Joining of dissimilar metals will offer many advantages in transportation sectors such as fuel consumption,weightreduction and emission reduction.However,joining of aluminium(Al)alloys with magnesium(Mg)alloys by fusion welding processis very complicated.Friction stir welding(FSW)is a feasible method to join these two dissimilar alloys.Mixing these two metalstogether in stir zone(SZ)leads to poor corrosion resistance.In this investigation,an attempt has been made to understand thecorrosion resistance of SZ of FSWed dissimilar joints of AA6061Al alloy and AZ31B Mg alloy.Potentiodynamic polarization testwas conducted by varying chloride ion concentration,pH value of the NaCl solution and exposure time.The corroded surfaces wereanalyzed using optical microscopy,scanning electron microscopy and XRD techniques.Of these three factors investigated,exposuretime is found to be the most significant factor to influence the corrosion behaviour of SZ of friction stir welded dissimilar joints ofAl/Mg alloys.

Surface modification of biomedical Mg-Ca and Mg-Zn-Ca alloys using selective laser melting: Corrosion behaviour, microhardness and biocompatibility

Magnesium alloys such as Mg–Ca and Mg–Zn–Ca are good orthopaedic materials;however their tendency to corrode is high.Herein we utilize selective laser melting(SLM)to modify the surface of these Mg alloys to simultaneously improve the corrosion behaviour and microhardness.The corrosion rate decreased from 2.1±0.2 mm/y to 1.0±0.1 mm/y for the laser-processed Mg–0.6Ca,and from 1.6±0.1 mm/y to 0.7±0.2 mm/y for laser-processed Mg–0.5Zn–0.3Ca.The microhardness increased from 46±1 HV to 56±1 HV for Mg–0.6Ca,and from 47±3 HV to 55±3 HV for Mg–0.5Zn–0.3Ca.In addition,good biocompatibility remained in the laser processed Mg alloys.The improved properties are attributed to laser-induced grain refinement,confined impurity elements,residual stress,and modified surface chemistry.The results demonstrated the potential of SLM as a surface engineering approach for developing advanced biomedical Mg alloys.

Pitting Corrosion Behaviour of Monel-400 Alloy in Chloride Solutions

Pitting corrosion behaviour of Monel-400 alloy in 3.5 wt pct NaCl sodium chloride solution has been investigated using the cyclic potentiodynamic anodic polarization technique. The effect of chloride ion concentration, pH values and difFerent temperatures on the pitting parameters were determined. The morphology of the pits produced after anodic polarization treatments was inspected by scanning electron microscope (SEM). The results indicated that, the increase in chloride ion concentration shifts Epit and Eprot of the alloy toward negative values and the pitting potential is much more dependent on pH value in the basic region. The breakdown of passivity with increasing temperature may be due to kinetic changes of passivating films and dissolution rate of the alloy in its passive state

Corrosion behaviour of as-cast ZK40 with CaO and Y additions

The microstructures of as-cast ZK40,ZK40 with 2%(mass fraction)CaO and ZK40 with 1%(mass fraction)Y were investigated,and the intermetallic phase morphology and the distribution were characterised.By having discrete intermetallic particles at the grain boundaries for the ZK40,the microstructure was modified to a semi-continuous network of intermetallic compounds along the grain boundaries for the ZK40 with CaO or Y additions.The CaO was not found in the microstructure.However,Ca was present in Ca2Mg6Zn3 intermetallic compounds which were formed during casting.Hydrogen evolution and electrochemical impedance spectroscopy tests revealed that the addition of CaO slightly enhanced the corrosion resistance whereas Y had a negative effect on the corrosion resistance of ZK40.Immersion tests showed that severe localised corrosion as well as corrosion along the intermetallic compounds played an important role in the corrosion process of ZK40-Y whereas the localised corrosion was not pronounced for ZK40 or ZK40?CaO alloys.Micro-segregation in theα-Mg matrix was notably higher for the ZK40 alloy compared with the modified alloys.The combination of this effect with a possible formation of a more stable corrosion layer for the ZK40-CaO was attributed as the main reason for an improved corrosion resistance for the ZK40-CaO alloy.

Corrosion behaviours of the dental magnetic keeper complexes made by different alloys and methods

The keeper and cast dowel-coping, as a primary component for a magnetic attachment, is easily subjected to corrosion in a wet environment, such as the oral cavity, which contains electrolyte-rich saliva, complex microflora and chewing behaviour and so on. The objective of this in vitro study was to examine the corrosion resistance of a dowel and coping-keeper complex fabricated by finish keeper and three alloys （cobalt-chromium, CoCr; silver-palladium-gold, PdAu; gold-platinum, AuPt） using a laser- welding process and a casting technique. The surface morphology characteristics and microstructures of the samples were examined by means of metallographic microscope and scanning electron microscope （SEM）. Energy-dispersive spectroscopy （EDS） with SEM provided elements analysis information for the test samples after 10% oxalic acid solution etching test. Tafel polarization curve recordings demonstrated parameter values indicating corrosion of the samples when subjected to electrochemical testing. This study has suggested that massive oxides are attached to the surface of the CoCr-keeper complex but not to the AuPt-keeper complex. Only the keeper area of cast CoCr-keeper complex displayed obvious intergranular corrosion and changes in the Fe and Co elements, Both cast and laser-welded AuPt-keeper complexes had the highest free corrosion potential, followed by the PdAu-keeper complex. We concluded that although the corrosion resistance of the CoCr-keeper complex was worst, the keeper surface passive film was actually preserved to its maximum extent. The laser-welded CoCr- and PdAu-keeper complexes possessed superior corrosion resistance as compared with their cast specimens, but no significant difference was found between the cast and laser-welded AuPt-keeper complexes. The Fe-poor and Cr-rich band, appearing on the edge of the keeper when casting, has been proven to be a corrosion-prone area.

Effect of Molybdate Ions on the Corrosion Behaviour of Ti Alloys

Titanium alloys are extensively used in power, chemical and petroleum industries as constructional materials for vessels and heat transfer tubes. Moreover they are candidate materials for nuclear waste disposal. These alloys have superior resistance to localized forms of corrosion compared to stainless steels and Ni-base alloys. However, this resistance is not as remarkable in crevice corrosion conditions in some aggressive media. Electrochemical corrosion tests were conducted on two ASTM Ti grades namely, Ti-2 and Ti-12 in extremely low pH acidic environment. Results indicated that Ti-2 has less resistance to both general and crevice corrosion attack than Ti-12. Both alloys possess better resistance to general corrosion than to crevice corrosion. Also, results showed that the molybdate addition improves remarkably the resistance of Ti-2 to both types of attack. The increase of molybdate ions concentration from 0.03 mol/L to 0.15 mol/L made Ti-2 to be as resistant as, or somewhat higher than, Ti-12. The elecrochemical findings were further supplemented by optical examination of the corroded surface.

The Study on the Corrosion Behaviour of Welded and Unwelded Medium Carbon Steel in Sodium Chloride(Nacl)Solutions

The research work was based on the study of the corrosion behaviour of the welded and un-welded medium carbon steel in sodium chloride solutions.The Sodium chloride solutions used are 1ml,2ml,3ml and 4ml for both welded and un-welded medium carbon steel in NaCl.The experiments were conducted in two ways,the weight loss analyses of measurements and using the electrochemical analyzer workstation to determine the potential dynamic of the samples.The samples for the weight loss measurements were prepared from rolled products obtained at the foundry shop.Two medium carbon steel materials were sourced with different chemical compositions as sample A and B.The materials were prepared to accommodate the experiments for the determination of welded and un-welded medium carbon steel.A total of sixty-eight(68)samples were produced,prepared and used for the weight loss measurements/analyses the experiments.Thirty-four of the samples each were prepared for both the welded and un-welded experiments.All the samples were produced and prepared through the use of various machining processes with the use of a lathe machine for planning,milling.Thirty-four(34)of the sample preparation were further welded in readiness of the experiments.Sixty-eight breakers were sourced for and used.Ten(10)other samples were used for the determination with the use of the electrochemical analyzer.The chemical compositions of the medium carbon steel were determined with the use of SPECTRO Analytical Instruments.A metallurgical inverted optical microscope was used to determine the microstructures of the materials.The Scanning Electron Microscopy with EDS was used to determine the morphologies of the materials.The thirty-four of the samples were welded this process was performed to determine the effects of welding on the material surrounding the weldments.These materials were made into sizes with the use of power hacksaw(i.e.2cm by 2cm).Other materials were prepared to 1cm x 1cm thickness from the same materials.The Tafel plot experiments and that of the open Circuit Potential Time(OCPT)were carried out with the use of Electrochemical Analyzer/Workstation.The Medium carbon steel materials were exposed for fifty-four(54)days,with an interval of 3days.The corrosion rates analyses were determined and the graphs of the corrosion rates(mm/yr.)and other parameters were used plotted against No of days exposed.

Corrosion Behaviour and Chloride Attack of Reinforcing Steel in Presence of Concrete Admixtures

Corrosion and electrochemical behaviour of reinforcing steel embedded in cement pastes with and without concrete admixtures used in Egypt to modify concrete properties have been studied. The influence of the admixtures on the corrosion resistance of the steel against chloride attack has been studied by using impressed current and impressed voltage techniques. The results indicate that the type and concentration of the used admixture have an important effect on the extent of chloride induced corrosion of the steel. The mechanism of corrosion of steel due to chloride attack was discussed. (Edited author abstract) 16 Refs.

Using fused filament fabrication to improve the tribocorrosion behaviour of 17-4 PH SS in comparison to other metal forming techniques

Fused filament fabrication(FFF)is one of the additive manufacturing processes which has gained more interest because of its simplicity and low-cost.This technology is similar to the conventional metal injection moulding(MIM)process,consisting of the feedstock preparation of metal powder and polymer binders,followed by layer-by-layer 3D printing(FFF)or injection(MIM)to create green parts and,finally,debinding and sintering.Moreover,both technologies provide near-dense parts.This work presents an in-depth study of the processing method’s influence.The porosity,microstructure,hardness,corrosion,and tribocorrosion behaviour are compared for 17-4 PH SS samples processed from powder by additive manufacturing using FFF and MIM,as well as conventional powder metallurgy(PM)samples.MIM samples exhibited the highest macro and microhardness,while corrosion behaviour was similar for both MIM and FFF samples,but superior in comparison to conventional PM samples.However,the FFF-as fabricated samples displayed a significant improvement in tribocorrosion resistance that could be explained by the higher proportion of delta ferrite and retained austenite in their microstructure.

Effects of Cu on Microstructure and Corrosion Behaviour of Hot-Rolled Mg-3Zn-1Y Alloys

The microstructure and corrosion behaviour of hot-rolled Mg-3Zn-1Y-xCu alloys(x=0,1,3,5,wt%)were investigated.Results show that all Mg-3Zn-1Y-xCu alloys mainly consist ofα-Mg matrix and Mg_(3)Zn_(6)Y phases.The addition of Cu element promotes the formation of MgZnCu phase,and the amount of MgZnCu phase is increased with the increase in Cu content.Electrochemical and immersion test results show that the corrosion resistance of Mg-3Zn-1Y-xCu alloys is deteriorated after Cu addition,which can be attributed to the influence of the microstructure of alloys and the properties of the formed corrosion product film.The MgZnCu phase with high electrochemical potential accelerates the micro-galvanic corrosion as strong cathodic sites,and the decreased protection effect of the corrosion product film results from the variation in PBR value of the related compounds.

Microstructure,Corrosion and Mechanical Properties of Medium-Thick 6061-T6 Alloy/T2 Pure Cu Dissimilar Joints Produced by Double Side Friction Stir Z Shape Lap-Butt Welding

A novel double side friction stir Z shape lap-butt welding(DS-FSZW)process was proposed to achieve excellent mechanical properties of Al/Cu medium-thick dissimilar joints.The influence of welding parameters on weld microstructure and properties of DS-FSZW joint were systematically investigated.It indicated that defect-free medium-thick Al/Cu DS-FSZW joint could be achieved under an optimal welding parameter.DS-FSZW joint was prone to form void defects in the bottom of the second-pass weld.The recrystallization mechanisms at the top and middle of the weld nugget zone(WNZ)were continuous dynamic recrystallization(CDRX)and geometric dynamic recrystallization(GDRX).While the major recrystallization mechanism at the bottom of the WNZ was GDRX.DS-FSZW joint of the optimal welding condition with 850 r/min-400 mm/min was produced with a continuous thin and crack-free IMCs layer at the Al/Cu interface,and the maximum tensile strength of this joint is 160.57 MPa,which is equivalent to 65.54%of pure Cu base material.Moreover,the corrosion resistance of Al/Cu DS-FSZW joints also achieved its maximum value at the optimal welding parameter of 850 r/min-400 mm/min.It demonstrates that the DS-FSZW process can simultaneously produce medium-thick Al/Cu joints with excellent mechanical performance and corrosion resistance.

In-situ AFM and quasi-in-situ studies for localized corrosion in Mg-9Al-1Fe-(Gd) alloys under 3.5 wt.% NaCl environment

Revealing the localized corrosion process of Mg alloy is considered as one of the most significant ways for improving its corrosion resistance.The reliable monitor should be high distinguishability and real-time in liquid environment.Herein,Mg-9Al-1Fe and Mg-9Al-1Fe-1Gd alloys were designed to highlight the impact of intermetallic on the corrosion behaviour.In-situ AFM with a special electrolyte circulation system and quasi-in-situ SEM observation were used to monitor the corrosion process of the designed alloys.SEM-EDS and TEM-SAED were applied to identify the intermetallic in the designed alloys,and their volta potentials were measured by SKPFM.According to the real-time and real-space in-situ AFM monitor,the corrosion process consisted of dissolution of anodicα-Mg phase,accumulation of corrosion products around cathodic phase and shedding of some fine cathodic phase.Then,the localized corrosion process of Mg alloy was revealed combined with the results of the monitor of corrosion process and Volta potential difference.

In situ laser deposition of NiTi intermetallics for corrosion improvement of Ti-6Al-4V alloy

NiTi intermetallic coatings were fabricated on the surface of Ti-6Al-4V alloy by melting Ni and Ti powders using laser metal deposition（LMD） process.The effects of NiTi reinforcement content on the microstructure,hardness and corrosion properties of the coatings were examined.The results show that the deposited coatings are characterized by NiTi,NiTi2 and NiTi3 intermetallic phases.An appreciable increase in corrosion resistance is obtained for all the coatings,and Ti55Ni45 coating shows the highest corrosion resistance;while coatings Ti50Ni50 and Ti45Ni55 follow in that succession.The reinforcement materials are proven to be corrosion resistant in the tested environment,and the effect of Ti is more dominant.

Microstructural, mechanical and corrosion characterization of an as-cast Mg-3Zn-0.4Ca alloy for biomedical applications

The as-cast Mg-3Zn-0.4Ca alloy shows a great potential to be used in biomedical applications due to its composition,mechanical properties and biodegradability.Zn and Ca appear naturally in the organism accomplishing vital functions.The alloy consists of an a-Mg matrix and a eutectic composed of a-Mg4-Ca2Mg6Zn3.The eutectic product enhances the mechanical properties of the studied alloy,causing strengthening and providing superior hardness values.In this alloy,cracks initiate at the intermetallic compounds and progress through the matrix because of the open network formed by the eutectics.Attending to the corrosion results,the eutectic product presents a noble potential compared to the a-Mg phase.For this reason,the corrosion progresses preferentially through the matrix,avoiding the(α-Mg+Ca2Mg6Zri3)eutectic product,when the alloy is in direct contact to Hank's solution.

Effect of Temperature and Chloride Ion Concentration on the Electrochemical Behaviour of Stainless Steel

The effect of temperature and chloride ion concentration on the electrochemical behaviour of austenitic-ferritic duplex stainless steel COR 25 in an aqueous solution of 60%H_3PO_4+4%H_2SO_4 is studied in this paper. The experiments show that the anodic active peak current on potentiodynamic polarization increases by an order of magnitude with an in- crease of temperature from 50℃ and with an increase of chloride ion from<1 mg/1 to 1500mg/1. Compared with the other materials tested, the austenitic-ferritic duplex stainless steel shows favourable corrosion characteristics in electrochemical tests,being comparable to the fully austenitic alloy Sanicro 28,which has a higher chromium and nickel content,and is much better than GX3CrNiMo2010.Corrosion of the duplex material is normally phase selec- tive,with phase boundary attack after unfavour- able heat treatments.

Effects of TiC addition on properties of laser particle deposited WC-Co-Cr and WC-Ni coatings

The mechanisms by which titanium carbide （TiC） improves the properties of tungsten carbide （WC） coatings deposited on duplex stainless steels using laser particle injection technique were investigated. The relationships between laser process parameters and the synthesized composite were studied. The morphologies and microstructures of the feedstock powders and composite coatings were characterized using scanning electron microscopy （SEM） and energy dispersive X-ray spectroscopy （EDX） techniques. Surface hardness of the composite layers was determined using the Vickers microhardness tester while its corrosion behaviour in 3.5%NaCl solution was investigated by potentiodynamic polarization curve measurement method. As a result of the laser treatment, microstructures characterized by hard ceramic particles with strong bonding to substrate were formed on the surface layer of the steels. The addition of TiC to WC resulted in microstructures free from cracks, pores and intermetallics which could be detrimental to the properties of the composites. High microhardness was observed and most of the coatings shifted the corrosion potential to more noble values with the pseudo-passive curve.

Corrosion evolution and behaviour of Al-2.1Mg-1.6Si alloy in chloride media

Owing to the importance of finding better methods and technologies for protecting against corrosion of aluminium alloys,research into the electrochemical characteristics of the corrosion is an ongoing concern.In this paper,the corrosion behaviour of Al-Mg-Si alloys in 3.5 wt% NaCl solution was investigated using multiple methods,including scanning electron microscopy(SEM),transmission electron microscopy(TEM),potentiodynamic polarisation measurement and electrochemical impedance spectroscopy(EIS).The results suggest that corrosion begins with dealloying of Mg,followed by conversion of MgSi particles into Al-Fe-Mn-Si particles.The corrosion rate increased until it reached a peak and then decreased.The increase in the corrosion rate may be attributed to an increased electrochemical driving force,which is produced by anodic dissolution between the matrix and residual MgSi particles.Additionally,the thin re-deposited layer of inert elements also plays an important role in accelerating the anodic process of the corrosion pit.The passivated corrosion pit and narrowed intergranular corrosion(IGC)pathway cause the area of active dissolution to decrease,thus reducing the corrosion rate.

Corrosion behavior of Al_(0.4)CoCu_(0.6)NiSi_(0.2)Ti_(0.25) high-entropy alloy coating via 3D printing laser cladding in a sulphur environment

High-entropy alloys(HEAs) are of great interest in materials science and engineering communities owing to their unique phase structure.HEAs are constructed with five or more principal alloying elements in equimolar or near-equimolar ratios.Therefore,they can derive their performance from multiple principal elements ratherthan a single element.In this work,three-dimensional printing laser cladding was applied to produce an Al_(0.4)CoCu_(0.6)NiSi_(0.2)Ti_(0.25) HEA coating.The experimental results confirmed that the laser cladding could be used to produce a thin coating of 120 μm in thickness.In the high-temperature laser cladding process,some Fe elements diffused from the substrate to the coating,forming a combination of face-centred cubic and body-centred cubic phase structures.The HEA coating metallurgically bonded well with the substrate.Owing to the increased dislocation density and number of grain boundaries,the HEA coating was harder and had a stronger hydrophobicity than X70 steel.The electrochemistry results showed that the HEA coating had better corrosion resistance than X70 steel.Aluminium oxides formed on the surface of the HEA coating had a certain protective effect.However,because of the laser cladding,the HEA coating generated cracks.In future work,the laser cladding technology will be improved and heat treatment will be implemented to prevent formation of cracks.

Mechanical properties and corrosion resistance of powder metallurgical Mg-Zn-Ca/Fe bulk metal glass composites for biomedical application

Magnesium(Mg)alloys can be regarded as the most promising biodegradable implant materials for orthopedic and stent applications due to their good biocompatibility and low Young’s modulus which is near to that of natural bone.However,its applicability is hindered because it exhibits a high corrosion rate in the physiological environments.In this work,we fabricated Mg_(66)Zn_(30)Ca_(4)/Fe bulk metallic glass composites via spark plasma sintering(SPS).We studied the influence of different contents of Fe on the properties of the composites.The results indicated that Fe was uniformly distributed on the surface of Mg_(66)Zn_(30)Ca_(4) metallic glass(MG)as a second phase,which led to an improvement in the corrosion resistance and mechanical strength.The standard potential of Mg_(66)Zn_(30)Ca_(4)/Fe bulk metallic glass(BMG)composites increased as compared to Mg_(66)Zn_(30)Ca_(4),while their mechanical strength improved from 355 MPa to 616 MPa.Furthermore,cytotoxicity was investigated via the CCK-8 assay and calcein-AM staining,which revealed that the extraction mediums diluted 6 times(EM×6)of the Mg_(66)Zn_(30)Ca_(4) and Mg_(66)Zn_(30)Ca_(4)/Fe did not cause cell toxicity on day 3 and 5,while the EM×6 of the Mg_(66)Zn_(30)Ca_(4) showed cytotoxicity on day 1,3 and 5.Thus,Mg_(66)Zn_(30)Ca_(4)/Fe BMG composites exhibit significant potential for fabricating implants with good mechanical strength and corrosion resistance.

Corrosion Evolution of Low Alloy Steel in Deaerated Bicarbonate Solutions

Corrosion evolution during immersion tests （up to 43 days） of NiCu steel in deaerated 0.1 mol/L bicarbonate solutions was investigated by electrochemical measurements, scanning electron microscopy （SEM） and X-ray diffraction （XRD）. Results show that NiCu steel transformed from the anodic dissolution in the early stage of immersion to a metastable passive state in the final stage as the open-circuit potential value shifted positively, which was aroused by the precipitation of corrosion products. This process was mainly promoted by the trace amount of oxygen. Simultaneously, dominant cathodic reaction transformed from the hydrogen evolution in early stage to reduction processes of corrosion products in later stages. Possible corrosion processes were discussed with the assistance of a corresponding Pourbaix diagram.