Macro- and micro-galvanic corrosion of friction stir welding 6061-T6 Al and C1100 Cu dissimilar joints
Friction stir welding (FSW) is one of the solid-state methods for welding dissimilar metals to inhibit the formation of intermetallic phases. The effect of the heterogeneous microstructures of FSW 6061-T6 Al and C1100 Cu dissimilar joints on corrosion in 3.5 wt % NaCl was studied, including macro- a...
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Elsevier
2025-01-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785424029156 |
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| author | Yi-Ting Wu I-Chung Cheng Chao-Sung Lin |
| author_facet | Yi-Ting Wu I-Chung Cheng Chao-Sung Lin |
| author_sort | Yi-Ting Wu |
| collection | DOAJ |
| description | Friction stir welding (FSW) is one of the solid-state methods for welding dissimilar metals to inhibit the formation of intermetallic phases. The effect of the heterogeneous microstructures of FSW 6061-T6 Al and C1100 Cu dissimilar joints on corrosion in 3.5 wt % NaCl was studied, including macro- and micro-galvanic corrosions. The stir zone contained Cu particles embedded in Al, and CuAl2 and Cu9Al4 intermetallic phases formed via interdiffusion between Al and Cu. Consequently, the microstructure of the stir zone was heterogeneous. The Volta potential measurement revealed that Cu had a Volta potential of +200–400 mV relative to Al. An immersion test of the entire dissimilar joint revealed that the macro-galvanic coupling between 6061-T6 Al and C1100 Cu accelerated the corrosion of the stir zone. The stir zone tested individually showed that Al/CuAl2/Cu9Al4/Cu micro-galvanic coupling resulted in a uniform Al oxide/hydroxide layer on Al. Conversely, the surface of CuAl2 was porous and rich in Cu because of the dealloying of Al. The corrosion was not uniform and concentrated in Al-rich phases (Al, CuAl2). Moreover, the macro-galvanic couple between 6061-T6 Al and C1100 Cu base metals accelerated the corrosion of the heterogeneous stir zone. This study fills the gap between micro- and macro-galvanic corrosion of FSW Al and Cu dissimilar joints, which are essential for the applications. |
| format | Article |
| id | doaj-art-3c171a5aa7414027bb16bf2fd4c55a14 |
| institution | Kabale University |
| issn | 2238-7854 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj-art-3c171a5aa7414027bb16bf2fd4c55a142025-01-19T06:25:30ZengElsevierJournal of Materials Research and Technology2238-78542025-01-0134866879Macro- and micro-galvanic corrosion of friction stir welding 6061-T6 Al and C1100 Cu dissimilar jointsYi-Ting Wu0I-Chung Cheng1Chao-Sung Lin2Department of Mechanical Engineering, National Taiwan University, 106, Taipei, TaiwanDepartment of Mechanical Engineering, National Taiwan University, 106, Taipei, TaiwanDepartment of Material Science and Engineering, National Taiwan University, 106, Taipei, Taiwan; Corresponding author. Department of Materials Science and Engineering, National Taiwan University, 1, Roosevelt Road, Section 4, Taipei, 106, Taiwan.Friction stir welding (FSW) is one of the solid-state methods for welding dissimilar metals to inhibit the formation of intermetallic phases. The effect of the heterogeneous microstructures of FSW 6061-T6 Al and C1100 Cu dissimilar joints on corrosion in 3.5 wt % NaCl was studied, including macro- and micro-galvanic corrosions. The stir zone contained Cu particles embedded in Al, and CuAl2 and Cu9Al4 intermetallic phases formed via interdiffusion between Al and Cu. Consequently, the microstructure of the stir zone was heterogeneous. The Volta potential measurement revealed that Cu had a Volta potential of +200–400 mV relative to Al. An immersion test of the entire dissimilar joint revealed that the macro-galvanic coupling between 6061-T6 Al and C1100 Cu accelerated the corrosion of the stir zone. The stir zone tested individually showed that Al/CuAl2/Cu9Al4/Cu micro-galvanic coupling resulted in a uniform Al oxide/hydroxide layer on Al. Conversely, the surface of CuAl2 was porous and rich in Cu because of the dealloying of Al. The corrosion was not uniform and concentrated in Al-rich phases (Al, CuAl2). Moreover, the macro-galvanic couple between 6061-T6 Al and C1100 Cu base metals accelerated the corrosion of the heterogeneous stir zone. This study fills the gap between micro- and macro-galvanic corrosion of FSW Al and Cu dissimilar joints, which are essential for the applications.http://www.sciencedirect.com/science/article/pii/S2238785424029156AluminumCopperFriction stir weldingGalvanic corrosionSEM/EBSDEIS |
| spellingShingle | Yi-Ting Wu I-Chung Cheng Chao-Sung Lin Macro- and micro-galvanic corrosion of friction stir welding 6061-T6 Al and C1100 Cu dissimilar joints Journal of Materials Research and Technology Aluminum Copper Friction stir welding Galvanic corrosion SEM/EBSD EIS |
| title | Macro- and micro-galvanic corrosion of friction stir welding 6061-T6 Al and C1100 Cu dissimilar joints |
| title_full | Macro- and micro-galvanic corrosion of friction stir welding 6061-T6 Al and C1100 Cu dissimilar joints |
| title_fullStr | Macro- and micro-galvanic corrosion of friction stir welding 6061-T6 Al and C1100 Cu dissimilar joints |
| title_full_unstemmed | Macro- and micro-galvanic corrosion of friction stir welding 6061-T6 Al and C1100 Cu dissimilar joints |
| title_short | Macro- and micro-galvanic corrosion of friction stir welding 6061-T6 Al and C1100 Cu dissimilar joints |
| title_sort | macro and micro galvanic corrosion of friction stir welding 6061 t6 al and c1100 cu dissimilar joints |
| topic | Aluminum Copper Friction stir welding Galvanic corrosion SEM/EBSD EIS |
| url | http://www.sciencedirect.com/science/article/pii/S2238785424029156 |
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