Review of the atmospheric corrosion of magnesium alloys

doi:10.1016/j.jmst.2019.05.001

Abstract

Abstract:

Mg atmospheric corrosion is induced by a thin surface aqueous layer. Controlling factors are microgalvanic acceleration between different phases, protection by a continuous second phase distribution, protection by corrosion products, and degradation of protective layers by aggressive species such as chloride ions. The Mg atmospheric corrosion rate increases with relative humidity (RH) and concentrations of aggressive species. Temperature increases the corrosion rate unless a protective film causes a decrease. O₂, SO₂ and NO₂ accelerate the atmospheric corrosion rate, whereas the corrosion rate is decreased by CO₂. The traditional gravimetric method can evaluate effectively the corrosion behavior of Mg alloys.

Key words: Magnesium, Magnesium alloys, Atmospheric corrosion

Hongguang Liu, Fuyong Cao, Guang-Ling Song, Dajiang Zheng, Zhiming Shi, Mathew S. Dargusch, Andrej Atrens. Review of the atmospheric corrosion of magnesium alloys[J]. J. Mater. Sci. Technol., 2019, 35(9): 2003-2016.

Figures/Tables 12

Table 1 Corrosion rates of pure Mg and Mg alloys in atmosphere and 3 wt.% NaCl solution.

Material	Atmosphere (mm y^-1)	NaCl solution (mm y^-1)
Pure Mg	0.20 [52]	2.7 [39]
AZ31B	0.04 [52]	2.3 [39]
AM60	0.03 [52]	14.0 [39]
AZ91	0.02 [52]	8.0 [39]

Fig. 1. (a) Mass change of pure Mg and Mg alloys with different Al contents exposed to 5 wt.% NaCl salt fog at 35 °C [63]. (b) Mass gain of pure Mg and Mg alloys with different Al content after exposure at 98% relative humidity and 50 °C [29].

Fig. 2. Schematic presentation of the dual-effect model of the secondary phase on the corrosion of Mg alloy [96].

Table 2 Approximate number of water monolayers on a metal surface at 25 °C and steady state conditions [104].

Relative humidity (%)	Number of water monolayers
20	1
40	1.5-2
60	2-5
80	5-10

Fig. 3. Influence of relative humidity on the weight loss of AZ91D and AM50 after 4 weeks of exposure at 25 °C and 35 °C, as summarized from [38].

Fig. 4. (a) Weight loss of AZ91D as a function of the amount of NaCl deposition (14,70,140,and 25 μm/cm2) after 4 weeks of exposure at 25 °C according to data reported in [38]. (b) Influence of the amount of NaCl deposition on the mass gain of AZ91 after 1,3,5 week(s) of exposure at 25 °C and 90% RH according to the data reported in [123].

Fig. 5. Corrosion rates calculated from weight loss results for (a) 99.97% Mg and (b) AM50 in the atmosphere containing 14 ug/cm2 NaCl deposition with and without CO2 at different temperatures [110].

Fig. 6. Mass gain of AZ91D Mg alloy in environments containing different concentrations of SO2 according to the data reported in [134].

Table 3 The relative humidity and corresponding saturated salt solutions at 25 °C and 35 °C [153].

Temperature, oC	Relative humidity,%
Temperature, oC	50	75	85	95
25	Mg(NO₃)₂·6H₂O	NaCl	KCl	K₂SO₄
35	Mg(NO₃)₂·6H₂O	NaCl	K₂CrO₄	K₂SO₄

Fig. 7. Schematic diagram of experiment set-up for the sub-zero atmospheric corrosion experiment [110]: (1) CO2 source, (2) flow meter, (3) dip cooler, (4) mixing chamber, (5) insulation, (6) stirrer, (7) solenoid valves, (8) wash bottles, (9) corrosion samples suspended by nylon string, (10) corrosion chambers, (11) temperature regulator, (12 and 13) humidifiers producing 95% RH air at the exposure temperature (-4 °C), (14) water +44% ethylene glycol at constant temperature, (15) needle valves, (16) manometer valve (17) dry purified air with a pressure of 6 bars [110].

Fig. 8. Schematic diagram of the experimental arrangement for thin electrolyte layer corrosion study: transverse cross-sectional view of the electrochemical cell and A-A directional view of the cell [151,152].

Fig. 9. Schematic diagram of the arrangement of micro-electrodes used for in-situ EIS measurement: (a) top view of the comb-like micro-electrodes; (b) optical micrograph of micro-electrodes in illustrating the distance between two copper plates [159].

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