Corrosion Evolution of High-Strength Aluminum Alloys in the Simulated Service Environment of Amphibious Aircraft in the Presence of Chloride and Bisulfite

doi:10.1007/s40195-021-01216-2

Abstract

Abstract:

The corrosion evolution of 2024-T351 and 7075-T651 aluminum alloys in the thin electrolyte layer (TEL) and wet-dry alternating cycle (WDAC) environment is studied in this work. The results show that in the TEL environment, the competitive effect between H⁺ that accelerates corrosion reactions and deposition of aluminum sulfate that impedes corrosion attacks exists during the corrosion exposure. The difference is that with increasing HSO₃^-, subsurface intergranular corrosion on 2024-T351 is promoted to form exfoliation corrosion eventually and the degree of exfoliation corrosion begins to decrease because the blocking effect of aluminum sulfate exceeds the expediting effect of H⁺. For 7075-T651, the corrosion area and the corrosion diameter decrease gradually, which is attributed to the HSO₃^--enhanced deposition of corrosion products and their blocking effect. In the WDAC environment, the corrosion processes of 2024-T351 and 7075-T651 are the acidic dissolution of the matrix during the soaking phase. When the HSO₃^- concentration is high enough (0.1 M), the inhibiting effect of aluminum sulfate becomes the dominant factor.

Key words: High-strength aluminum alloy, Atmospheric corrosion · HSO3-, Intergranular corrosion, Exfoliation corrosion

Feng Ge, Lin Fan, Jianming Liang, Kun Pang, Han Li, Xin Wang, Zhongyu Cui. Corrosion Evolution of High-Strength Aluminum Alloys in the Simulated Service Environment of Amphibious Aircraft in the Presence of Chloride and Bisulfite[J]. Acta Metallurgica Sinica (English Letters), 2021, 34(12): 1679-1694.

Figures/Tables 12

Fig. 1 Optical micrographs a, b and intermetallic particle distributions c, d of 2024-T351 a, c and 7075-T651 b, d aluminum alloys

Fig. 2 Schematic diagram of the set-up and the specimens corroded in the TEL a and WDAC b environments

Fig. 3 Change of the relative humidity and the temperature in the chamber within one cycle: a TEF corrosion test, b WDAC corrosion test

Fig. 4 Weight loss a, c, e, g and corrosion rate b, d, f, h of 2024-T351 a-d and 7075-T651 e-h aluminum alloys after immersion in the TEL a, b, e, f and WDAC c, d, g, h environments for different cycles

Fig. 5 Corrosion morphologies of 2024-T351 aluminum alloy after exposure in 3.5 wt% NaCl TEL environments without a1-a3 and with 0.001 M b1-b3, 0.01 M c1-c3 and 0.1 M d1-d3 HSO3- for 2 a1-d1, 8 a2-d2, and 16 a3-d3 cycles

Fig. 6 Corrosion morphologies of 2024-T351 aluminum alloy after exposure in 3.5 wt% WDAC environments without a1-a3 and with 0.001 M b1-b3, 0.01 M c1-c3 and 0.1 M d1-d3 HSO3- for 2 a1-d1, 8 a2-d2, and 16 a3-d3 cycles

Fig. 7 Corrosion morphologies of 7075-T651 aluminum alloy after exposure in 3.5 wt% NaCl TEL environments without a1-a3 and with 0.001 M b1-b3, 0.01 M c1-c3 and 0.1 M d1-d3 HSO3- for 2 a1-d1, 8 a2-d2, and 16 a3-d3 cycles

Fig. 8 Corrosion morphologies of 7075-T651 aluminum alloy after exposure in 3.5 wt% WDAC environments without a1-a3 and with 0.001 M b1-b3, 0.01 M c1-c3 and 0.1 M d1-d3 HSO3- for 2 a1-d1, 8 a2-d2, and 16 a3-d3 cycles

Fig. 9 Geometrical parameters including the mean corrosion depth a, e, corrosion diameter b, f, individual corrosion volume c, g, and corrosion shape d, h of 2024-T351 aluminum alloy after exposure in TEL a-d and WDAC e-h environments for different corrosion time

Fig. 10 Geometrical parameters including the mean corrosion depth a, e, corrosion diameter b, f, individual corrosion volume c, g, and corrosion shape d, h of 7075-T651 aluminum alloy after exposure in TEL a-d and WDAC e-h environments for different corrosion time

Fig. 11 Optical micrographs a1-a4, c1-c4 and SEM images b1-b4, d1-d4 of the cross-sectional morphologies of 2024-T351 aluminum alloy after corrosion in 3.5 wt% NaCl TEL a1-a4, b1-b4 and WDAC c1-c4, d1-d4 environments without a1-d1 and with 0.001 M a2-d2, 0.01 M a3-d3, and 0.1 M a4-d4 HSO3- for 12 cycles

Fig. 12 Optical micrographs a1-a4, c1-c4 and SEM images b1-b4, d1-d4 of the cross-sectional morphologies of 7075-T651 aluminum alloy after corrosion in 3.5 wt% NaCl TEL a1-a4, b1-b4 and WDAC c1-c4, d1-d4 environments without a1-d1 and with 0.001 M a2-d2, 0.01 M a3-d3, and 0.1 M a4-d4 HSO3- for 12 cycles

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