Uyime Donatus

In this study, the intergranular corrosion (IGC) susceptibility of AA2098‐T351 welds, fabricated through friction stir welding (FSW), was systematically evaluated. The evaluation employed American Society for Testing and Materials (ASTM) G110‐92 practice and electrochemical impedance measurements, with comparative analyses against unwelded alloys (BS). The key findings depicted that FSW‐induced microstructure changes significantly influenced IGC susceptibility across different zones. Zones affected by FSW presented distinct susceptibilities compared with the base metal (BM). The ASTM G110‐92 test effectively differentiated the heat‐affected zone (HAZ) into segments with changing corrosion resistances based on welding temperature gradients. Cross‐sectional analyses using scanning electron microscopy (SEM) techniques correlated corrosion characteristics with microstructural features identified by transmission electron microscopy (TEM). Overall, FSW‐induced microstructural alterations emerged as a predominant factor influencing the varying susceptibilities of different zones to IGC, and electrochemical impedance measurements (EIS) validated the findings from ASTM G110‐92 practice.

In this study, the behaviour of the micrometric particles of the AA2198-T8 alloy during anodising at various voltages and the effect of anodising voltage on the anodised surface morphology have been investigated in a tartaric-sulfuric acid anodising solution. The results were compared with that of the AA2024-T3 alloy. For the AA2198-T8 alloy, partial dissolution of these particles occurred at 0, 3 and 4 V. Besides, for potentials above 5 V, there is a preferential dissolution of the intermetallic particles. For the AA2024-T3 alloy, the results indicated a total dissolution of the micrometric particles at 0 V and a partial dissolution at 3 V, whereas above 4 V total dissolution occurred. Between 1 and 2 V, no dissolution was observed for both alloys. The preferential dissolution of the micrometric particles resulted in defects in the anodic film and cavities on the anodised surfaces. GRAPHICAL ABSTRACT

The effect of different surface treatments on the corrosion resistance of the AA2098 Al–Cu–Li alloy has been investigated. Surface characterization was performed using 3D optical profilometry, energy dispersive X-ray spectroscopy and scanning electron microscopy. The corrosion resistance of the 2098 alloy after the surface treatments was investigated in 0.1 mol L ⁻¹ NaCl solution by electrochemical techniques and microscopy. Corrosion results showed that the untreated and the chemically etched surfaces were more active than the mechanically abraded and mechanically polished surfaces owing to differences in the nature of the native oxides formed after the surface treatments. Corrosion rate and mode were also affected by how close the exposed surface was to the mid-thickness region of the AA2098-T351 plate relative to the actual top surface (before polishing). This is associated with the variation in the volume fraction and distribution of the T1 phase as the mid-thickness region of the AA2098-T351 plate is approached.

The susceptibility to localised corrosion of the high strength alloys, AA2050-T84 and AA7050-T7451, used in the aerospace industry, was investigated in this study by localised electrochemical techniques, specifically, scanning vibrating electrode technique (SVET) and scanning ion-selective electrode technique (SIET), in 0.005 mol L⁻¹ NaCl solution. The study was initially carried out using both alloys individually and then, coupling the two alloys and evaluating the effect of galvanic coupling between them. The results revealed that the AA2050-T84, being nobler than the AA7050-T7451, presented higher corrosion current density values when tested in isolation and the depth of corrosion penetration was significantly deeper in the AA2050-T84 alloy than in the AA7050-T7451. However, galvanic coupling of the two alloys resulted in cathodic protection of the AA2050-T84 alloy and a reduction in corrosion current densities on both alloys.

The corrosion resistance of conventional (AA2024-T3, AA6082-T6 and AA7050-T7451) and the new generation (AA2050-T84, AA2098-T351, AA2198-T8, and AA2198-T851) precipitation-hardened alloys has been studied and compared using electrochemical and non-electrochemical approaches. The AA6082-T6 was the most resistant alloy followed by the new generation Al-Cu-Li alloys, except the AA2050-T84. All the alloys exhibited pseudo-passivity, except for the AA2024-T3 alloy which presented the highest number of pitting sites per cm2 and also exhibited the most insidious form of corrosion amongst the alloys tested. However, the alloy with the highest corrosion depth was the AA2050-T84 alloy followed by the AA2024-T3 and AA7050-T7451 alloys. Intergranular corrosion was associated with rapid rates of penetration. In addition to the microstructural features of the alloys before corrosion, the modes of localized corrosion in the alloys were also influenced by evolving microstructural features (such as re-deposited Cu) during corrosion.

The development of severe localised corrosion (SLC) on the 2198-T8 alloy was investigated in solutions of various NaCl concentrations (0.001, 0.005 and 0.01 mol L⁻¹). Immersion tests, optical profilometry, conventional and local electrochemical analyses were performed to evaluate the corrosion behaviour of the alloy. Immersion tests showed that the alloy is susceptible to SLC in all conditions, although the pits sizes were dependent on the solution concentration. The largest anodic areas, corresponding to SLC sites, were observed for the sample immersed in 0.001 mol L⁻¹ NaCl, whereas pits with similar sizes were observed for the samples immersed in solutions with 0.005 and 0.01 mol L⁻¹ of NaCl. Moreover, the maximum depth of attack was observed for the sample immersed in 0.001 mol L⁻¹ NaCl. These results were in agreement with the scanning ion-selective electrode technique (SIET) maps which showed stronger acidification on the sample exposed to 0.001 mol L⁻¹ NaCl solution.

In this work, a surface coating composed of organic‐inorganic hybrid sol‐gel based on bis‐1,2‐(triethoxysilyl) (BTSE) ethane was applied on AA2198‐T8 samples, and its effect on corrosion resistance was investigated and compared with that of a chromate layer formed in a solution with hexavalent chromium ions. The corrosion resistance of BTSE coated samples was evaluated by immersion tests in sodium chloride solution (0.005 mol/L NaCl) and monitored by global electrochemical techniques such as electrochemical impedance spectroscopy (EIS) and local electrochemical techniques such as scanning vibrating electrode technique (SVET) and scanning electrochemical microscopy (SECM). The formed coating layers were characterized by X‐ray photoelectron spectroscopy (XPS). The results pointed out that the BTSE is an effective alternative coating for corrosion protection of new generation Al‐Cu‐Li alloys and could replace chromates obtained in toxic and carcinogenic CrVI containing solutions leading to improved corrosion protection.

In this work, scanning electrochemical microscopy (SECM) measurements were employed to characterize the electrochemical activities on polished and as‐received surfaces of the 2098‐T351 aluminum alloy (AA2098‐T351). The effects of the near surface deformed layer (NSDL) and its removal by polishing on the electrochemical activities of the alloy surface were evaluated and compared by the use of different modes of SECM. Confocal laser scanning microscopy (CLSM) and scanning electron microscopy (SEM) were also employed to characterize the morphology of the surfaces. The surface chemistry was analyzed by X‐ray photoelectron spectroscopy (XPS). The surface generation/tip collection (SG/TC) and competition modes of the SECM were used to study hydrogen gas (H ₂ ) evolution and oxygen reduction reactions, respectively. H ₂ evolution and oxygen reduction were more pronounced on the polished surfaces. The feedback mode of SECM was adopted to characterize the electrochemical activity of the polished surface that was previously corroded by immersion in a chloride‐containing solution, in order to investigate the influence of the products formed on the active/passive domains. The precorroded surface and as‐received surfaces revealed lower electrochemical activities compared with the polished surface showing that either the NSDL or corrosion products largely decreased the local electrochemical activities at the AA2098‐T351 surfaces.

The influence of T3, T8 and T851 thermomechanical treatments on the microstructure and corrosion resistance of the AA2198 was investigated. Differential scanning calorimetry and scanning electron microscopy were used for microstructural characterisation, whereas electrochemical methods were employed to analyse the corrosion behaviour of the alloy. The morphology and composition of constituent particles were similar for the T3 and T8 thermomechanical treatments but varied in the T851. There was an inverse relation between T1 phase density and corrosion resistance. The T3 treatment with the highest corrosion resistance was the one with the lowest density of T1 phase. The mechanisms of corrosion varied with the thermomechanical treatments.