A Review on Tribocorrosion Behavior of Aluminum Alloys: From Fundamental Mechanisms to Alloy Design Strategies
<p>Summary of literature review of tribocorrosion papers published from 1973–2023. (<b>a</b>) Annual production, (<b>b</b>) Trending topics, and (<b>c</b>) Most relevant journals.</p> "> Figure 2
<p>(<b>a</b>) Material loss from pure wear (V<sub>M0</sub>), pure corrosion (V<sub>C</sub>), and corrosion-induced wear (ΔV<sub>M</sub>) of Al Alloy in artificial seawater at different applied potentials (Replotted from Ref. [<a href="#B63-cmd-04-00031" class="html-bibr">63</a>]). (<b>b</b>) Potentiodynamic polarization curves of 7075-T6 alloy under various hydrostatic pressure levels in a 3.5 wt.% NaCl solution (Replotted from Ref. [<a href="#B64-cmd-04-00031" class="html-bibr">64</a>]).</p> "> Figure 3
<p>(<b>a</b>) Mass loss evolution of Al–Cu alloy with various Cu concentrations from pin-on-disk wear tests over 500 m sliding distance (Replotted from Ref. [<a href="#B69-cmd-04-00031" class="html-bibr">69</a>]). (<b>b</b>) Wear rate versus square root of grain size (d<sup>0.5</sup>) of nanocrystalline Al under severe and mild wear (Replotted from Ref. [<a href="#B75-cmd-04-00031" class="html-bibr">75</a>]). (<b>c</b>) EBSD maps and (<b>d</b>) 3D profiles of wear track of additively manufactured Al-5 wt.%Cu-1.5 wt.%Ti and Al-5 wt.%Cu samples after ball-on-disk wear tests under 10 N load for a sliding time of 30 min. (Replotted from Ref. [<a href="#B70-cmd-04-00031" class="html-bibr">70</a>]).</p> "> Figure 4
<p>(<b>a</b>) SEM micrographs of corroded surfaces of Al alloys after immersion in 0.01 M NaCl solution for 24 h for pure Al and 108 h for all Al–Mn alloys (Replotted from Ref. [<a href="#B93-cmd-04-00031" class="html-bibr">93</a>]). (<b>b</b>) Corrosion current and grain size of Al follows a Hall–Petch type relationship (Replotted from Ref. [<a href="#B100-cmd-04-00031" class="html-bibr">100</a>]).</p> "> Figure 5
<p>Schematic summary of relevant mechanisms influencing the tribocorrosion performance of passive metals in corrosive environment. This original schematic was created by the authors for this study.</p> "> Figure 6
<p>Summary of wear rate versus corrosion of Al-based alloys from literature review. Plotted using data obtained from Refs. [<a href="#B124-cmd-04-00031" class="html-bibr">124</a>,<a href="#B125-cmd-04-00031" class="html-bibr">125</a>]. Al–HEA represents AlxCo1.5CrFeNi1.5Tiy high-entropy alloys, Al–BMG represents Al90.05Y4.4Ni4.3Co0.9Sc0.35 bulk metallic glasses, and 1xxx, 5xxx, and 6xxx represents different series of Al alloys.</p> "> Figure 7
<p>Summary of (<b>a</b>) Hardness (H); (<b>b</b>) Pitting potential (E<sub>pit</sub>); and (<b>c</b>) Corrosion current density (i<sub>corr</sub>) as a function of alloying concentration in binary Al–X systems [<a href="#B93-cmd-04-00031" class="html-bibr">93</a>,<a href="#B118-cmd-04-00031" class="html-bibr">118</a>,<a href="#B129-cmd-04-00031" class="html-bibr">129</a>,<a href="#B130-cmd-04-00031" class="html-bibr">130</a>,<a href="#B131-cmd-04-00031" class="html-bibr">131</a>,<a href="#B132-cmd-04-00031" class="html-bibr">132</a>,<a href="#B133-cmd-04-00031" class="html-bibr">133</a>,<a href="#B134-cmd-04-00031" class="html-bibr">134</a>,<a href="#B135-cmd-04-00031" class="html-bibr">135</a>,<a href="#B136-cmd-04-00031" class="html-bibr">136</a>] (replotted from Ref. [<a href="#B49-cmd-04-00031" class="html-bibr">49</a>]). (<b>d</b>) Dependence of hardness (H), corrosion potential (E<sub>corr</sub>), pitting potential (E<sub>pitt</sub>), and corrosion current (i<sub>corr</sub>) as a function of Mo concentration in Al–Mo binary alloy (plotted using data from [<a href="#B134-cmd-04-00031" class="html-bibr">134</a>]).</p> "> Figure 8
<p>Summary of microstructure corrosion behavior of Al–Mn supersaturated solid solutions in 0.6 M NaCl electrolyte. (<b>a</b>) Potentiodynamic polarization curves and their corresponding transmission electron microscopy images of pure Al, Al-5.2 at.% Mn, Al-11.5 at.% Mn, and Al-20.5 at.% Mn. (<b>b</b>) Relationship between pitting potential and manganese concentration with different phases. Replotted from Refs. [<a href="#B49-cmd-04-00031" class="html-bibr">49</a>,<a href="#B93-cmd-04-00031" class="html-bibr">93</a>].</p> "> Figure 9
<p>(<b>a</b>) Corrosion current and (<b>b</b>) Corrosion potential of Al–Mn solid solutions with 0–40 at.% Mn. (<b>c</b>) Schematic summary of how Mn addition influences the passive layer protectiveness. Replotted from Ref. [<a href="#B137-cmd-04-00031" class="html-bibr">137</a>].</p> "> Figure 10
<p>(<b>a</b>) Evolution of open circuit potential; (<b>b</b>) Summary of material loss from wear, corrosion, and synergy; (<b>c</b>) Material loss as a function of applied potential; and (<b>d</b>) Temporal evolution of tribocorrosion current at 200 mV anodic potential of Al and Al–Mn alloys after tribocorrosion tests in 3.5 wt.% NaCl solutions. Replotted from Refs. [<a href="#B49-cmd-04-00031" class="html-bibr">49</a>,<a href="#B93-cmd-04-00031" class="html-bibr">93</a>].</p> "> Figure 11
<p>(<b>a</b>) Corrosion current of Al–Mn solid solutions with 0–40 at.% Mn. (<b>b</b>) Schematic summary of how Mn addition influences the passive layer protectiveness. Replotted from Ref. [<a href="#B62-cmd-04-00031" class="html-bibr">62</a>].</p> "> Figure 12
<p>Summary of wear rate versus corrosion of Al-based alloys from literature review. Strategy 1 indicates the formation of supersaturated solid solution. Plotted using data obtained from Refs. [<a href="#B49-cmd-04-00031" class="html-bibr">49</a>,<a href="#B93-cmd-04-00031" class="html-bibr">93</a>,<a href="#B124-cmd-04-00031" class="html-bibr">124</a>,<a href="#B125-cmd-04-00031" class="html-bibr">125</a>]. Al–HEA represents AlxCo1.5CrFeNi1.5Tiy high-entropy alloys, Al–BMG represents Al90.05Y4.4Ni4.3Co0.9Sc0.35 bulk metallic glasses, and 1xxx, 5xxx, and 6xxx represents different-series of Al alloys.</p> "> Figure 13
<p>(<b>a</b>) Schematic of Al/X NMM structure; (<b>b</b>) Evolution of open circuit potential (OCP) during tribocorrosion; and (<b>c</b>) Potentiodynamic polarization curves of Al/X (X = Ti, Mg, and Cu) in 3.5 wt.% NaCl. Replotted from Ref. [<a href="#B142-cmd-04-00031" class="html-bibr">142</a>].</p> "> Figure 14
<p>Finite element (FE) simulation results of (<b>a</b>–<b>c</b>) von Mises stress distribution after wear; and (<b>d</b>–<b>f</b>) von Mises strain and current density distribution after tribocorrosion in 0.6 M NaCl aqueous solution of Al/Ti, Al/Mg, and Al-Cu NMMs. Replotted from Ref. [<a href="#B142-cmd-04-00031" class="html-bibr">142</a>].</p> "> Figure 15
<p>Summary of (<b>a</b>) 1/H vs. i<sub>corr</sub> of all monolithic and NMM samples; and (<b>b</b>) wear versus corrosion rate of all samples in the present work, as well as 1xxx, 5xxx, and 6xxx Al alloys, Al-based high entropy alloys (HEA), and Al-based bulk metallic glasses (BMG) tested under similar conditions.</p> "> Figure 16
<p>Summary of the FE tribocorrosion model setup and geometry (<b>a</b>) Before; (<b>b</b>) During; and (<b>c</b>) After the tribocorrosion test. (<b>d</b>) Schematic of the local electrochemical parameter mapping as a function of the lattice reorientation and dislocation density. Replotted from Ref. [<a href="#B147-cmd-04-00031" class="html-bibr">147</a>].</p> "> Figure 17
<p>(<b>a</b>) Nanoindentation results and (<b>b</b>) Potentiodynamic polarization curves of Al (100), (110), and (111) single crystals in 3.5 wt.% NaCl solution. Tribocorrosion current evolution of experimentally measured profiles v.s. finite element analysis simulated profiles (<b>c</b>) Without and (<b>d</b>) With consideration of subsurface dislocation effects. Replotted from Ref. [<a href="#B147-cmd-04-00031" class="html-bibr">147</a>].</p> "> Figure 18
<p>Summary of tribocorrosion rate maps predicted via multiphysics modeling. Material volume loss (<b>a</b>) from mechanical wear and (<b>b</b>–<b>d</b>) chemical wear as a function of (<b>a</b>,<b>b</b>) yield strength and Young’s modulus, and (<b>c</b>,<b>d</b>) electrochemical properties of Al-based alloys. Replotted from Ref. [<a href="#B157-cmd-04-00031" class="html-bibr">157</a>].</p> "> Figure 19
<p>Summary of (<b>a</b>) Three alloy design strategies and (<b>b</b>) Relevant tribocorrosion mechanism of metals due to the alloy design.</p> ">
Abstract
:1. Introduction
2. Brief History and Literature Survey from the Past Five Decades
3. Effects of Alloying and Grain Size on Wear Resistance of Al Alloys
3.1. Alloying Effects
3.2. Grain Size Effects
4. Effects of Alloying and Grain Size on Corrosion Resistance of Al Alloys
4.1. How Does Alloying Affect Corrosion of Al Alloys?
4.2. Does Corrosion Resistance Depend on Grain Size?
5. Tribocorrosion Behavior and Mechanisms of Al Alloys
6. Tribocorrosion Resistance of Al Alloys
7. How to Design Tribocorrosion-Resistant Al Alloys?
7.1. Strategy 1: Formation of Supersaturated Solid Solutions
7.1.1. Alloying Effects on Corrosion
7.1.2. Alloying Effects on Tribocorrosion and Wear-Corrosion Synergy
7.2. Strategy 2: Formation of Nanostructured Multilayers
7.3. Strategy 3: Formation of Preferred Crystallographic Textures
8. Current Challenges and Outlook
9. Summary
Funding
Data Availability Statement
Conflicts of Interest
References
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Zhang, Z.; Dandu, R.S.B.; Klu, E.E.; Cai, W. A Review on Tribocorrosion Behavior of Aluminum Alloys: From Fundamental Mechanisms to Alloy Design Strategies. Corros. Mater. Degrad. 2023, 4, 594-622. https://doi.org/10.3390/cmd4040031
Zhang Z, Dandu RSB, Klu EE, Cai W. A Review on Tribocorrosion Behavior of Aluminum Alloys: From Fundamental Mechanisms to Alloy Design Strategies. Corrosion and Materials Degradation. 2023; 4(4):594-622. https://doi.org/10.3390/cmd4040031
Chicago/Turabian StyleZhang, Zhengyu, Raja Shekar Bhupal Dandu, Edwin Eyram Klu, and Wenjun Cai. 2023. "A Review on Tribocorrosion Behavior of Aluminum Alloys: From Fundamental Mechanisms to Alloy Design Strategies" Corrosion and Materials Degradation 4, no. 4: 594-622. https://doi.org/10.3390/cmd4040031