Enhanced Corrosion Resistance by Pseudomonas aeruginosa on 2219 Aluminum Alloy Manufactured Through Additive Friction Stir Deposition

doi:10.1007/s40195-025-01906-1

Abstract

Abstract:

In this work, the effect of Pseudomonas aeruginosa (P. aeruginosa) on the corrosion behavior of 2219 aluminum alloy manufactured through additive friction stir deposition (AFSD) was investigated. Under sterile conditions, a large number of corrosion products appeared on the sample surface, and the maximum corrosion pit depth reached 5.98 μm after 7 days of immersion. In the presence of P. aeruginosa, the sample surface was extensively colonized by a substantial biofilm, and the maximum pit depth was only 2.88 μm after 7 days of immersion. In addition, electrochemical tests demonstrated a two orders of magnitude reduction in corrosion current density compared to the sterile conditions. The scanning electrochemical microscopy (SECM) results also showed a weakening in the cathodic oxygen reduction process on the sample surface under inoculation conditions. The corrosion resistance of 2219 aluminum alloy manufactured through AFSD was enhanced by the colonization of P. aeruginosa biofilm, primarily attributed to the protective effect exerted by extracellular polymeric substances (EPS) within the P. aeruginosa biofilm.

Key words: Microbiologically influenced corrosion, Aluminum alloy, Additive friction stir deposition, Corrosion

Zhongyu Wu, Hongchang Qian, Weiwei Chang, Zhixiong Zhu, Yongyong Lin, Qian Qiao, Dawei Guo, Dawei Zhang, Chi Tat Kwok, Lap Mou Tam. Enhanced Corrosion Resistance by Pseudomonas aeruginosa on 2219 Aluminum Alloy Manufactured Through Additive Friction Stir Deposition[J]. Acta Metallurgica Sinica (English Letters), 2025, 38(11): 1935-1952.

Figures/Tables 20

Table 1 Chemical compositions of the 2219 aluminum alloy (wt%)

Si	Fe	Cu	Mn	Zn	Ti	V	Zr	Al
0.05	0.08	6.30	0.33	0.04	0.07	0.12	0.18	Bal.

Fig. 1 Schematic diagram of AFSD process and the deposition path

Fig. 2 Schematic diagram of immersion tests

Fig. 3 pH variation of the sterile and the P. aeruginosa-inoculated culture medium during 7 days of immersion

Fig. 4 Surface SEM morphologies of the AFSD samples after a1, a2 1 day, b1, b2 3 days, c1, c2 7 days of immersion in sterile culture medium

Table 2 Quality percentages of elements from EDS results (wt%)

	Al	C	O	Cu	Fe	P	Ca
Sterile medium
Point a	70.6	20.1	5.3	4.0	0.0	0.0	0.0
Point b	43.7	23.7	21.0	4.0	4.7	1.7	1.2
Inoculated medium
Point a	50.1	43.7	3.8	2.1	0.3	0.0	0.0

Fig. 5 Surface SEM morphologies of the AFSD samples after a1, a2 1 day, b1, b2 3 days, c1, c2 7 days of immersion in the P. aeruginosa-inoculated culture medium

Fig. 6 a1 XPS overview spectra and high-resolution spectra of b1 Al 2p, c1 C 1s, and d1 O 1s on the surfaces of AFSD samples after 7 days of immersion in sterile culture medium; a2 XPS overview spectra and high-resolution spectra of b2 Al 2p, c2 C 1s, d2 O 1s on the surfaces of AFSD samples after 7 days of immersion in P. aeruginosa-inoculated culture medium

Fig. 7 Evolution of a Nyquist plots and b Bode plots of the AFSD samples during 7 days of immersion in sterile culture medium; evolution of c Nyquist plots, d Bode plots of the AFSD samples during 7 days of immersion in P. aeruginosa-inoculated culture medium

Fig. 8 Equivalent electrical circuit for fitting the EIS plots

Table 3 EIS parameters of samples after different days of immersion in sterile and P. aeruginosa-inoculated culture media

	R_s (Ω cm²)	Q_c × 10^-6 (Ω⁻¹ cm⁻² sⁿ)	R_c × 10³ (Ω cm²)	Q_dl × 10^-5 (Ω⁻¹ cm⁻² sⁿ)	R_ct × 10⁴ (Ω cm²)	χ² × 10^-4
In the sterile culture medium
1 d	23.71	10.31	11.3	1.36	0.71	4.70
3 d	23.72	15.11	4.00	2.83	0.91	10.9
5 d	24.17	17.73	2.69	2.64	1.61	6.43
7 d	24.16	22.21	2.44	2.97	1.50	4.45
In the P. aeruginosa-inoculated culture medium
1 d	12.27	9.96	51.0	0.27	8.15	6.75
3 d	12.45	7.30	13.2	0.26	173.8	2.88
5 d	11.54	7.56	8.44	0.23	87.9	1.47
7 d	11.75	6.54	6.45	0.25	68.1	1.26

Fig. 9 Potentiodynamic polarization curves for the AFSD samples after 7 days of immersion in sterile and P. aeruginosa-inoculated culture media

Table 4 Parameters from the potentiodynamic polarization curves after 7 days of immersion in sterile and P. aeruginosa-inoculated culture media

	E_corr (V)	I_corr (A cm⁻²)
Inoculated medium	− 0.72	1.27 × 10^-8
Sterile medium	− 0.56	1.42 × 10^-6

Fig. 10 CV curve of the UME in 1 mM FcMeOH solution

Fig. 11 SECM images of the AFSD samples after 1 day of immersion in a sterile, b P. aeruginosa-inoculated culture media

Fig. 12 Corrosion pit morphologies of the AFSD samples after 3 d of immersion in a, b the sterile culture medium and c P. aeruginosa-inoculated culture medium; d average distribution density of corrosion pits on the sample surfaces after 1 d and 3 d of immersion in the sterile and P. aeruginosa-inoculated media

Fig. 13 Maximum depth of the corrosion pits on the surface of AFSD samples after a 1 day, b 3 days, c 7 days of immersion in sterile culture medium

Fig. 14 Maximum depth of the corrosion pits on the surfaces of AFSD samples after a 1 day, b 3 days, c 7 days of immersion in P. aeruginosa-inoculated culture medium

Fig. 15 a Average depth of corrosion pits on AFSD samples after different days of immersion in sterile and P. aeruginosa-inoculated culture media; b results of weight loss tests after different days of immersion in sterile and P. aeruginosa-inoculated culture media

Fig. 16 a1, a2 EIS results of AFSD sample with the coverage of EPS after sterilization, b1, b2 EIS results of AFSD sample with EPS and live cells reimmersed in a new sterile medium

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