Development of ultra-high strength and corrosion-resistant aluminum (Al) alloys is demonstrated by a combination of suitable alloying elements and processing technology able to cause extended solid solubility and nanocrystalline structure. Binary Al-transition metal (M: Cr, Ni, Mo, Si, Ti, Mn, V, Nb) alloys, produced by high-energy ball milling and subsequent cold compaction, have exhibited significantly high hardness and corrosion resistance compared to any commercial Al alloy. The cyclic potentiodynamic polarization tests revealed a significant improvement in pitting and repassivation potentials. X-ray diffraction analysis revealed the grain refinement < 100 nm and extended solid solubility. IMPACT STATEMENT High-energy ball-milled Al alloys, owing to excellent corrosion resistance and high hardness, are expected to be a new class of Al alloys and initiate a multidisciplinary research direction.

Commercial aluminum alloys exhibit localized corrosion when exposed to environments containing aggressive anions. Alloying of Al with specific elements (M: Cr, Mo, V, Nb, etc) using non-equilibrium processing techniques has been reported to result in significantly improved corrosion resistance due to the formation of a supersaturated solid solution and uniform distribution of M in the matrix. Several theories describing the corrosion behavior of Al–M alloys have been postulated. This paper presents an overview of the most common non-equilibrium alloying techniques implemented for the production of the metastable Al–M alloys and posited corrosion mechanisms for the improved corrosion resistance.

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