Corrosion of Cast Aluminum Alloys: A Review
<p>(<b>a</b>) Typical macrostructure of an Al–6 wt %, Cu–1 wt % Si alloy, (<b>b</b>) representation of the transverse surface samples used in the corrosion tests, and (<b>c</b>) experimental and simulated Cu and Si profiles corresponding to positions close to the casting surface highlighting the Cu macrosegregation. Reprinted with permission of [<a href="#B2-metals-10-01384" class="html-bibr">2</a>].</p> "> Figure 2
<p>SEM micrographs and EDS analysis performed in (<b>a</b>) AlSi<sub>7</sub>Mg and (<b>b</b>) AlSi<sub>10</sub>Mg, respectively. Reprinted with permission of [<a href="#B4-metals-10-01384" class="html-bibr">4</a>].</p> "> Figure 3
<p>Microstructure images of A356 cast samples with different Sr addition (<b>a</b>) No Sr addition, (<b>b</b>) 120 ppm, (<b>c</b>) 170 ppm, and (<b>d</b>) 250 ppm. Reprinted with permission of [<a href="#B5-metals-10-01384" class="html-bibr">5</a>].</p> "> Figure 4
<p>(<b>a</b>) Change in corrosion density as a function of immersion time. (<b>b</b>) Schematic presentation of oxide layer formation at the surface of AA EN-AlSi7Mg0.3 during the course of immersion in artificial sea water with added Na<sub>2</sub>S. Reprinted with permission of [<a href="#B7-metals-10-01384" class="html-bibr">7</a>].</p> "> Figure 5
<p>SEM micrographs of the initial stages of corrosion attack of A356 (<b>a</b>,<b>b</b>) and A356Nd (<b>c</b>,<b>d</b>) alloys as a function of time: (<b>a</b>,<b>c</b>) 1 h, (<b>b</b>,<b>d</b>) 8 h. Reprinted with permission of [<a href="#B9-metals-10-01384" class="html-bibr">9</a>].</p> "> Figure 6
<p>Weight loss rate curves of ADC12-xYb aluminum alloys immersed in 3.5 wt % NaCl solution for 10, 20, 30 days. Reprinted with permission from Elsevier [<a href="#B11-metals-10-01384" class="html-bibr">11</a>].</p> "> Figure 7
<p>Micrographs of the AlSiCu alloy injected at different combinations of temperature and pressure (<b>a</b>) 579 °C/35 MPa, (<b>b</b>) 579 °C/70 MPa, (<b>c</b>) 643 °C/35 MPa, (<b>d</b>) 643 °C/70 MPa, (<b>e</b>) 709 °C/35 MPa, and (<b>f</b>) 709 °C/70 MPa, respectively. Reprinted with permission of [<a href="#B15-metals-10-01384" class="html-bibr">15</a>].</p> "> Figure 8
<p>(<b>a</b>) Macrostructure representation at CET and (<b>b</b>) average values of secondary dendrite arm spacing for Al–5 wt-%Cu and Al–8 wt-%Cu alloys. Reprinted with permission of [<a href="#B18-metals-10-01384" class="html-bibr">18</a>].</p> "> Figure 9
<p>Scanning electron micrographs of the cross section of the RRA B206 aluminum alloy after m 48 h of immersion in artificial seawater showing exfoliation corrosion for a scale bar of 40 µm (<b>a</b>) and 30 µm (<b>b</b>,<b>c</b>). Reprinted with permission of [<a href="#B21-metals-10-01384" class="html-bibr">21</a>].</p> "> Figure 10
<p>Optical micrographs of cast aluminum alloys after corrosion tests. Reprinted with permission of [<a href="#B23-metals-10-01384" class="html-bibr">23</a>].</p> "> Figure 11
<p>(<b>a</b>) Typical macrostructure of the as-cast Al–5 wt % Ni alloy and schematic representation of positions from where the samples were extracted for corrosion tests and (<b>b</b>) optical micrographs with corresponding dendritic spacings (<span class="html-italic">λ</span><sub>1</sub> and <span class="html-italic">λ</span><sub>2</sub> are the primary and secondary dendritic spacings, respectively) and cooling rates. Reprinted with permission of [<a href="#B24-metals-10-01384" class="html-bibr">24</a>].</p> "> Figure 12
<p>Cyclic polarization curves of A356-GC and A-356-RC aluminum alloys after 1 h immersion in 3.5% NaCl naturally aerated solution. Reprinted with permission of [<a href="#B41-metals-10-01384" class="html-bibr">41</a>].</p> "> Figure 13
<p>Corroded surfaces of (<b>a</b>) 2.5RG and (<b>b</b>) 4.5 RG after polarization test in the diluted Harrison solution. Reprinted with permission of [<a href="#B43-metals-10-01384" class="html-bibr">43</a>].</p> "> Figure 14
<p>Schematic illustrations showing the corrosion behavior in Al–12Si as-prepared SLM, heat-treated SLM, and the cast samples under acidic environment. Reprinted with permission of [<a href="#B75-metals-10-01384" class="html-bibr">75</a>].</p> "> Figure 15
<p>FIB-SEM micrograph of the corroded area in cross-section taken from the anodized sample by liquid casting. Reprinted with permission of [<a href="#B98-metals-10-01384" class="html-bibr">98</a>].</p> "> Figure 16
<p>Microstructures of samples: (<b>a</b>) alloy A (2.43 wt % Si), high cooling rate; (<b>b</b>) alloy C (5.45 wt % Si), high cooling rate; (<b>c</b>) alloy C M (5.45 wt % Si), high cooling rate; (<b>d</b>) alloy C M (5.45 wt % Si), low cooling rate. Reprinted with permission of [<a href="#B99-metals-10-01384" class="html-bibr">99</a>].</p> "> Figure 17
<p>STEM-EDXS micrographs of the anodized layer containing Si flakes (alloy C): (<b>a</b>) STEM micrograph; (<b>b</b>) EDXS elemental map. Reprinted with permission of [<a href="#B99-metals-10-01384" class="html-bibr">99</a>].</p> "> Figure 18
<p>High magnification STEM micrographs of Si flakes inside oxide layer: (<b>a</b>) STEM micrograph; (<b>b</b>) bulk plasmon energy map of the selected area highlighting the oxide regions; (<b>c</b>) bulk plasmon energy map of the selected area highlighting the elemental Si and Al domains. Reprinted with permission of [<a href="#B99-metals-10-01384" class="html-bibr">99</a>].</p> "> Figure 19
<p>Corrosion rate for coated and uncoated A356.0 substrates after 120 h immersion as determined by weight loss experiments. Reprinted with permission of [<a href="#B108-metals-10-01384" class="html-bibr">108</a>].</p> "> Figure 20
<p>Schematic presentation of the self-sealing mechanism of zirconium conversion coating applied on AlSi7Mg0.3 during its immersion in 0.5 M NaCl solution. Reprinted with permission of [<a href="#B109-metals-10-01384" class="html-bibr">109</a>].</p> ">
Abstract
:1. Introduction
2. Corrosion Resistance of Cast Aluminum Alloys
2.1. Series 3xx.x
2.1.1. Corrosion Resistance of Cast Aluminum Alloys Obtained by Gravity Castings
2.1.2. Influence of Addition of Rare Earths on Corrosion Resistance
2.1.3. Corrosion Resistance of Cast Aluminum Alloys Obtained by High Pressure Die Casting (HPDC)
2.2. Series Other than 3xx.x
2.2.1. Series 1xx.x
2.2.2. Series 2xx.x
2.2.3. Series 4xx.x
2.2.4. Series 5xx.x
2.2.5. Series 9xx.x
3. Corrosion Resistance of Cast Aluminum Alloys Obtained by Semi Solid Manufacturing (SSM)
4. Corrosion Resistance of Cast Aluminum Alloys Obtained by Additive Manufacturing (AM)
5. Corrosion Resistance of Coatings Obtained by Different Surface Treatments
6. Summary and Conclusions
- Corrosion studies of cast aluminum alloys to date have used, in many cases, non-standard alloys in different electrolytes using a range of different corrosion test methods (such as EIS, polarization testing, SKPM, immersion test) making rigorous comparisons difficult. Likewise, there are no studies of long exposures in atmospheric environments, so it is difficult to make long-term predictions.
- In general, corrosion rates measured in neutral chloride media and sulphurated media of cast aluminum alloys can be considered low as they range from 0.5 10–6 to 5. On the contrary, corrosion resistance in basic saline media and acidic media is low.
- The pitting corrosion resistance is not good as the passivation ranges are very small. In addition, intergranular corrosion has also been detected in some studies. This tendency has been observed as the main rule for all aluminum cast series.
- The influence of the characteristic microstructural and macrostructural variables of aluminum alloys—such as grain size, SDAS values, eutectic silicon morphology, and size and nature of intermetallic compounds—on corrosion resistance is complex as there are combined effects between them. In general, higher cooling rates, and the addition of silicon modifier elements improve corrosion resistance while intermetallic compound formation and pore formation decrease corrosion rate. Nevertheless, more work is needed to reach clear conclusions about the individual effect of each microstructural issue on corrosion resistance.
- The addition of rare earth elements (RE) has been shown to improve pitting corrosion resistance as they promote the formation of intermetallic compounds with less tendency to form galvanic couples.
- Corrosion behavior of SSM Al alloys has been checked, demonstrating that mainly Al-Si alloys by rheocasting occupy the major attention in scientific literature, it being that the SSM corrosion performance is higher than cast alloys of identical chemical composition.
- Corrosion study of SSM Al alloys needs more attention since it is a promising technique to obtain close to net final shape of important Al components, mainly of use in the automotive and aerospace industries. Thus, extensive efforts are required to develop tests to characterize corrosion behavior in realistic industrial conditions.
- There is restrictive information about corrosion behavior of AM components in literature. The most studied alloy is AlSi10Mg due to its excellent mechanical strength and corrosion properties in cast state and this has been the basis to be processed by AM. Direct metal laser sintering (DMLS) is the most employed process for this alloy.
- Pitting corrosion is a common form of attack for AM aluminum alloys studied; nevertheless, uniform corrosion, fatigue corrosion and intergranular corrosion have also been observed. Surface roughness associated with AM process must be modified to improve its corrosion behavior. On the other hand, post thermal treatments balance microstructural changes in order to decrease corrosion attack of Al due to the role of cathode Si particles as cathodes.
- Development of new Al alloys with Sc and Zr as promising corrosion resistant materials due to lower level of porosity, controlled microstructure, and good performance against post manufacturing thermal treatment is being observed.
- Different surface treatments—such as anodizing process, sol–gel deposition technique, plasma electrolytic oxidation (PEO), or conversion electrolytic coatings, among others—can be good alternatives for improving the resultant corrosion resistance of the aluminum alloys. The resultant electrochemical corrosion properties have been evaluated in depth for the uncoated and coated materials by using electrochemical techniques such as potentiodynamic curves and electrochemical impedance spectroscopy. In all cases, the coated materials showed remarkably reduced susceptibility to corrosion and significantly increased coating impedance.
Supplementary Materials
Author Contributions
Funding
Conflicts of Interest
References
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Berlanga-Labari, C.; Biezma-Moraleda, M.V.; Rivero, P.J. Corrosion of Cast Aluminum Alloys: A Review. Metals 2020, 10, 1384. https://doi.org/10.3390/met10101384
Berlanga-Labari C, Biezma-Moraleda MV, Rivero PJ. Corrosion of Cast Aluminum Alloys: A Review. Metals. 2020; 10(10):1384. https://doi.org/10.3390/met10101384
Chicago/Turabian StyleBerlanga-Labari, C., M. V. Biezma-Moraleda, and Pedro J. Rivero. 2020. "Corrosion of Cast Aluminum Alloys: A Review" Metals 10, no. 10: 1384. https://doi.org/10.3390/met10101384