Effect of Friction Stir Processing on Pitting Corrosion and Intergranular Attack of 7075 Aluminum Alloy

Abstract

Abstract:

The effect of friction stir processing (FSP) on the pitting corrosion and the intergranular attack of 7075 aluminum alloy was investigated. Three friction stir processed samples were produced by employing a constant tool travel speed of 100?mm/min at the rotating speeds of 630, 1000 and 1600?rpm. It was demonstrated that the processed samples suffered from both pitting and intergranular corrosion. Also, the sample processed at 1600?rpm exhibited the best pitting corrosion resistance. For all FS processed samples, the corrosion attack in the heat affected zone was pitting corrosion, whereas no intergranular corrosion was detected in this area.

Key words: Al alloy, Friction stir processing, Pitting corrosion, Intergranular corrosion

Navaser M,Atapour* M. Effect of Friction Stir Processing on Pitting Corrosion and Intergranular Attack of 7075 Aluminum Alloy[J]. J. Mater. Sci. Technol., 2017, 33(2): 155-165.

Figures/Tables 21

Table 1 Chemical composition of 7075 aluminum alloy used in this investigation

Zn	Mg	Cu	Cr	Fe	Mn	Si	Ti	Al
5.4	2.3	1.63	0.337	0.204	0.176	0.0891	0.0112	Balance

Table 2 FS processing parameters used in this study

Rotational speed (rpm)	Travel speed (mm/min)
630	100
1000	100
1600	100

Fig. 1 Tool employed in the present study

Fig.2 Surface appearance of the FS processed specimens: (a) FSP630, (b) FSP1000, and (c) FSP1600

Fig.3 Cross-sectional micrograph for FS630, showing the positions for microstructure examinations. The top, middle, and bottom regions are evident

Fig.4 Optical microstructure of the as-received BM

Fig.5 Typical macroscopic view of the transverse section of FS processed specimens

Fig.6 Optical microstructures of the stir zones obtained at different rotational speeds: (a) the middle of FSP630, (c) the middle of FSP1000, (e) the middle of FSP1600 and (g) the top of FSW1600 at low magnification and (b) the top of FSP630, (d) the top of FSP1000, (f) the top of FSP1600 and (h) the top of FSW1600 at high magnification

Fig.7 Optical micrographs of the transition zone between TMAZ and the stir zone of FSP1600 on the (a) AS and (b) RS

Fig.8 SEM images of FSP1600, showing the intermetallic distribution in (a) stir zone, (b) TMAZ, (c) HAZ

Fig.9 FE-SEM images of the distribution of intermetallic particles in (a) BM, and the top surface of (b) FSP630, (c) FSP1000, and (d) FSP1600

Fig.10 XRD patterns of (a) BM, (b) FSP630, (c) FSP1000, (d) FSP1600

Fig.11 Representative EDS analysis on the BM and FS processed samples

Fig.12 Vickers microhardness profiles at the top surface of FS processed specimens at different rotational speeds

Fig.13 Open circuit potential vs. time plots recorded for the BM and different FS processed specimens in aerated 3.5% NaCl

Fig.14 Cyclic polarization curves of the BM and different FS processed specimens measured in 3.5% NaCl solution

Table 3 Various electrochemical parameters obtained from cyclic polarization measurements in 3.5 wt% NaCl

Samples	Ecorr (mV)	icorr (µA/cm²)	Ipass (µA/cm²)	R_p(Ω cm²)	Epit (mV)	Erp (mV)	Erp-Ecor (mV)	Epit-Ecor (mV)	Epit-Erp (mV)
BM	-1077?±?13	14.9?±?0.7	79	8034	-665	-755	315	405	90
FSP630	-1070±12	15.7?±?2.1	69.5	7653	-745	-837	226	318	92
FSP1000	-1044?±?9	14.3?±?2	58	7196	-716	-830	219	333	114
FSP1600	-1061?±?6	12.4?±?1.6	38.8	9058	-710	-855	205	350	145

Fig.15 OM images of (a) BM, (b) FSP630, (c) FSP1000, (d) FSP1600, after 9 days of immersion in 3.5% NaCl

Fig.16 Optical and SEM micrographs showing the surface morphology of the FSP1600 after 9 days of immersion in 3.5% NaCl: (a, c) TMAZ, (b, d) HAZ

Fig.17 SEM micrographs of different stir zones after 24 hours of IGC test in NaCl?+?H2O2: (a) FSP630, (b) FSP1000, (c) FSP1600

Fig.18 High magnification SEM micrographs of the surface morphology of (a) TMAZ of FSP 1000, (b) HAZ of FSP1000, (c) BM, and (d) the low magnification SEM micrograph of FS processed at 1000?rpm

References

[1]	R.S. Mishra, Z.Y. Ma,Mater. Sci. Eng. R, 50(2005), pp. 1-78
[2]	W.M. Thomas, D. Nicholas, J.C. Needham, M.G. Murch, P. Templesmith, C.J. Dawes,Friction Stir Welding, International Patent Appl. No. PCT/GB92(1991)
[3]	M. Chiumenti, M. Cervera, C. Agelet de Saracibar, N. Dialami,Comput. Meth. Appl. Mech. Eng, 254(2013), pp. 353-369
[4]	Z. Ma,Metall. Mater. Trans. A, 39(2008), pp. 642-658
[5]	T.S. Mahmoud,Surf. Coat. Technol, 228(2013), pp. 209-220
[6]	Z.Y. Ma, S.R. Sharma, R.S. Mishra,Mater. Sci. Eng. A, 433(2006), pp. 269-278
[7]	B. Li, Y. Shen, W. Hu, L. Luo,Surf. Coat. Technol, 239(2014), pp. 160-170
[7]	C.B. Fuller, M.W. Mahoney, M. Calabrese, L. Micona
8	Mater. Sci. Eng.A, 527(2010), pp. 2233-2240
[9]	T.J. Harrison, B.R. Crawford, M. Brandt, G. Clark,Comput. Mater. Sci, 84(2014), pp. 74-82
[10]	K. Jones, D.W. Hoeppner,Int. J. Fatigue, 31(2009), pp. 686-692
[11]	A.C. Fraker, A.W.Ruff Jr.,Corros. Sci, 10(1970), pp. 191-195
[12]	J.R. Davis,Corrosion of Aluminum and Aluminum Alloys,ASM International, Materials Park, OH (1999)
[13]	J.B. Lumsden, M.W. Mahoney, G. Pollock, C.G. Rhodes,Corrosion, 55(1999), pp. 1127-1135
[14]	C. Paglia, M. Carroll, B. Pitts, T. Reynolds, R. Buchheit,Strength, Mater. Sci. Forum, 396(2002), pp. 1677-1684
[15]	G. Elatharasan, V.S.S.Kumar,J. Mech. Eng, 60(2014), pp. 29-34
[16]	Y. Mao, L. Ke, F. Liu, Q. Liu, C. Huang, L. Xing,Mater. Des, 62(2014), pp. 334-343
[17]	F. Zhang, X. Su, Z. Chen, Z. Nie,Mater. Des, 67(2015), pp. 483-491
[18]	I. Fridlyander, A. Dobromyslov, E. Tkachenko, O. Senatorova,Met. Sci. Heat Treat, 47(2005), pp. 269-275
[19]	K. Surekha, B. Murty, K.P. Rao,Solid State Sci, 11(2009), pp. 907-917
[20]	F.J. Humphreys,Recrystallization and Related Annealing Phenomena
[20]	Pergamon (1995)
[21]	W. Xu, J. Liu, H. Zhu,Mater. Des, 32(2011), pp. 2000-2005
[22]	R. Moshwan, F. Yusof, M.A. Hassan, S.M. Rahmat,Mater. Des, 66(2015), pp. 118-128
[23]	W. Xu, J. Liu, H. Zhu, L. Fu,Mater. Des, 47(2013), pp. 599-606
[24]	J.Q. Li, H.J. Liu,Mater. Des, 45(2013), pp. 148-154
[25]	C. Sharma, D.K. Dwivedi, P. Kumar,Mater. Sci. Eng. A, 620(2015), pp. 107-119
[26]	K. Surekha, B.S. Murty, K.P. Rao,Surf. Coat. Technol, 202(2008), pp. 4057-4068
[27]	H. Sarlak, M. Atapour, M. Esmailzadeh,Mater. Des, 66(2015), pp. 209-216
[28]	O. Hatamleh, P.M. Singh, H. Garmestani,Corros. Sci, 51(2009), pp. 135-143
[29]	C.G. Rhodes, M.W. Mahoney, W.H. Bingel, R.A. Spurling, C.C. Bampton,Scr. Mater, 36(1997), pp. 69-75
[30]	J.Q. Su, T. Nelson, R. Mishra, M. Mahoney,Acta Mater, 51(2003), pp. 713-729
[31]	W. Xu, J. Liu,Corros. Sci, 51(2009), pp. 2743-2751
[32]	H. Bisadi, A. Tavakoli, M. Tour Sangsaraki, K. Tour Sangsaraki,Mater. Des, 43(2013), pp. 80-88
[33]	E. Cerri, P. Leo,Mater. Des, 31(2010), pp. 1392-1402
[34]	A. Elrefaey, K. Anders, H. Kilian, F. Ellermann, W. Kuehlein,Weld. J., 93(2014), pp. 451S-457S
[35]	E. Cerri, P. Leo,Mater. Chem. Phys, 147(2014), pp. 1123-1133
[36]	W. Xu, J. Liu, G. Luan, C. Dong,Mater. Des, 30(2009), pp. 3460-3467
[37]	M. Conserva, M. Buratti, E. Di Russo, F. Gatto,Mater. Sci. Eng, 11(1973), pp. 103-112
[38]	W. Xu, J. Liu, G. Luan, C. Dong,Mater. Des, 30(2009), pp. 1886-1893
[39]	R.D. Fu, Z.Q. Sun, R.C. Sun, Y. Li, H.J. Liu, L. Liu,Mater. Des, 32(2011), pp. 4825-4831
[40]	O. Meydanoglu, B. Jodoin, E.S. Kayali,Surf. Coat. Technol, 235(2013), pp. 108-116
[41]	L. Kobotiatis, N. Pebere, P.G. Koutsoukos,Corros. Sci, 41(1999), pp. 941-957
[42]	M.A. Amin,Corros. Sci, 52(2010), pp. 3243-3257
[43]	S.J. Kalita,Appl. Surf. Sci, 257(2011), pp. 3985-3997
[44]	S. Cramer, L. McDonald,Corrosion Testing and Evaluation: Silver Anniversary Volume, vol.1000, ASTM STP (1990), p. 241
[45]	A. Balyanov, J. Kutnyakova, N. Amirkhanova, V. Stolyarov, R. Valiev, X. Liao, Y. Zhao, Y. Jiang, H. Xu, T. Lowe,Scr. Mater, 51(2004), pp. 225-229
[46]	G. Argade, S. Panigrahi, R. Mishra,Corros. Sci, 58(2012), pp. 145-151
[47]	L. Shreir, R. Jarman, G. Burstein,Corrosion (Metal/Environment Reactions), vol. 1, vol. 4, Butterworth-Heinemann, Oxford, England(1994), p. 44
[48]	S.Z.El Abedin, A. Saleh,J. Appl. Electrochem, 34(2004), pp. 331-335
[49]	S. Lakshmi Priya, A. Chitra, S. Rajendran, K. Anuradha,Surf. Eng, 21(2005), pp. 229-231
[50]	S. Khireche, D. Boughrara, A. Kadri, L. Hamadou, N. Benbrahim,Corros. Sci, 87(2014), pp. 504-516
[51]	E. Bousquet, A. Poulon-Quintin, M. Puiggali, O. Devos, M. Touzet,Corros. Sci, 53(2011), pp. 3026-3034
[52]	T. Huang, S. Zhao, G. Frankel, D. Wolfe,Corrosion, 63(2007), pp. 819-827
[53]	M. Bagheri Hariri, S. Gholami Shiri, Y. Yaghoubinezhad, M. Mohammadi Rahvard,Mater. Des, 50(2013), pp. 620-634
[54]	M. Jariyaboon, A.J. Davenport, R. Ambat, B.J. Connolly, S.W. Williams, D.A. Price,Corros. Sci, 49(2007), pp. 877-909
[55]	T. Ramgopal, P. Gouma, G. Frankel,Corrosion, 58(2002), pp. 687-697
[56]	T. Ramgopal, P. Schmutz, G. Frankel,J. Electrochem.Soc, 148(2001), pp. B348-B356
[57]	S. Maitra, G. English,Metall. Trans. A, 12(1981), pp. 535-541
[58]	M. Atapour, A. Pilchak, G. Frankel, J. Williams,Corros. Sci, 52(2010), pp. 3062-3069

[1]	Lin Yuan, Jiangtao Xiong, Yajie Du, Jin Ren, Junmiao Shi, Jinglong Li. Microstructure and mechanical properties in the TLP joint of FeCoNiTiAl and Inconel 718 alloys using BNi2 filler [J]. J. Mater. Sci. Technol., 2021, 61(0): 176-185.
[2]	Yanan Pu, Wenwen Dou, Tingyue Gu, Shiya Tang, Xiaomei Han, Shougang Chen. Microbiologically influenced corrosion of Cu by nitrate reducing marine bacterium Pseudomonas aeruginosa [J]. J. Mater. Sci. Technol., 2020, 47(0): 10-19.
[3]	Enze Zhou, Jianjun Wang, Masoumeh Moradi, Huabing Li, Dake Xu, Yuntian Lou, Jinheng Luo, Lifeng Li, Yulei Wang, Zhenguo Yang, Fuhui Wang, Jessica A. Smith. Methanogenic archaea and sulfate reducing bacteria induce severe corrosion of steel pipelines after hydrostatic testing [J]. J. Mater. Sci. Technol., 2020, 48(0): 72-83.
[4]	Yanjin Lu, Xiongcheng Xu, Chunguang Yang, Ling Ren, Kai Luo, Ke Yang, Jinxin Lin. In vitro insights into the role of copper ions released from selective laser melted CoCrW-xCu alloys in the potential attenuation of inflammation and osteoclastogenesis [J]. J. Mater. Sci. Technol., 2020, 41(0): 56-67.
[5]	Piao Gao, Wenpu Huang, Huihui Yang, Guanyi Jing, Qi Liu, Guoqing Wang, Zemin Wang, Xiaoyan Zeng. Cracking behavior and control of β-solidifying Ti-40Al-9V-0.5Y alloy produced by selective laser melting [J]. J. Mater. Sci. Technol., 2020, 39(0): 144-154.
[6]	Zhangweijia Qiu, Zhengkun Li, Huameng Fu, Hongwei Zhang, Zhengwang Zhu, Aimin Wang, Hong Li, Long Zhang, Haifeng Zhang. Corrosion mechanisms of Zr-based bulk metallic glass in NaF and NaCl solutions [J]. J. Mater. Sci. Technol., 2020, 46(0): 33-43.
[7]	Bingqiang Wei, Song Ni, Yong Liu, Xiaozhou Liao, Min Song. Phase transformation and structural evolution in a Ti-5at.% Al alloy induced by cold-rolling [J]. J. Mater. Sci. Technol., 2020, 49(0): 211-223.
[8]	Hao Jin, Qing Jia, Quangang Xian, Ronghua Liu, Yuyou Cui, Dongsheng Xu, Rui Yang. Seeded growth of Ti-46Al-8Nb polysynthetically twinned crystals with an ultra-high elongation [J]. J. Mater. Sci. Technol., 2020, 54(0): 190-195.
[9]	Y.H. Gao, L.F. Cao, J. Kuang, J.Y. Zhang, G. Liu, J. Sun. Dual effect of Cu on the Al₃Sc nanoprecipitate coarsening [J]. J. Mater. Sci. Technol., 2020, 37(0): 38-45.
[10]	S.G. Wang, M. Sun, S.Y. Liu, X. Liu, Y.H. Xu, C.B. Gong, K. Long, Z.D. Zhang. Synchronous optimization of strengths, ductility and corrosion resistances of bulk nanocrystalline 304 stainless steel [J]. J. Mater. Sci. Technol., 2020, 37(0): 161-172.
[11]	Yuqiao Dong, Yassir Lekbach, Zhong Li, Dake Xu, Soumya El Abed, Saad Ibnsouda Koraichi, Fuhui Wang. Microbiologically influenced corrosion of 304L stainless steel caused by an alga associated bacterium Halomonas titanicae [J]. J. Mater. Sci. Technol., 2020, 37(0): 200-206.
[12]	Shucai Zhang, Huabing Li, Zhouhua Jiang, Zhixing Li, Jingxi Wu, Binbin Zhang, Fei Duan, Hao Feng, Hongchun Zhu. Influence of N on precipitation behavior, associated corrosion and mechanical properties of super austenitic stainless steel S32654 [J]. J. Mater. Sci. Technol., 2020, 42(0): 143-155.
[13]	Jianlu Pei, Yefan Li, Chong Li, Zumin Wang, Yongchang Liu, Huijun Li. Microstructure-dependent oxidation behavior of Ni-Al single-crystal alloys [J]. J. Mater. Sci. Technol., 2020, 52(0): 162-171.
[14]	Suyun Liu, Li Liu, Ying Li, Fuhui Wang. Effects of N-alkylation on anticorrosion performance of doped polyaniline/epoxy coating [J]. J. Mater. Sci. Technol., 2020, 39(0): 48-55.
[15]	Di Zhang, Zhen Zhang, Yanlin Pan, Yanbin Jiang, Linzhong Zhuang, Jishan Zhang, Xinfang Zhang. Current-driving intergranular corrosion performance regeneration below the precipitates solvus temperature in Al-Mg alloy [J]. J. Mater. Sci. Technol., 2020, 53(0): 132-139.