In the present study, the effects of mechanical polishing on the microstructure and corrosion behaviour of AA7075 aluminium alloy are investigated. It was found that a nano-grained, near-surface deformed layer, up to 400 nm thickness, is developed due to significant surface shear stress during mechanically polishing. Within the near-surface deformed layer, the alloying elements have been redistributed and the microstructure of the alloy is modified; in particular, the normal MgZn 2 particles for T6 are absent. However, segregation bands, approximately 10-nm thick, containing mainly zinc, are found at the grain boundaries within the near-surface deformed layer. The presence of such segregation bands promoted localised corrosion along the grain boundaries within the near-surface deformed layer due to microgalvanic action. During anodic polarisation of mechanically polished alloy in sodium chloride solution, two breakdown potentials were observed at −750 mV and −700 mV, respectively. The first breakdown potential is associated with an increased electrochemical activity of the near-surface deformed layer, and the second breakdown potential is associated with typical pitting of the bulk alloy.

An innovative solution for the automotive industry is to replace the copper used for wiring harnesses with aluminum alloys, such as the aluminum-magnesium-silicon 6101 alloy. Wiring harnesses are composed of thin strand arms obtained by a wire drawing process. These strands are susceptible to exposure to a corrosive environment and fatigue solicitations simultaneously. The fatigue endurance of this alloy was studied using the stress-life approach for three metallurgical states representative of three colddrawing steps. Fatigue tests performed in corrosive media tests highlighted a strong decrease of the 6101 alloy lifetime due to fatigue-corrosion interactions and a modification of failure modes.