Corrosion Resistance of Fe-Contaminated Al-Si-CU-Zn Alloys Modified With NI and Co and with Variable Secondary Dendrite Arm Spacing

Abstract

The corrosion behavior of Fe-containing directionally solidified (DS) and centrifugally cast (CC) Al-Si-Cu-Zn alloys with either Co or Ni additions has been investigated. Electrochemical and immersion corrosion methods were used to investigate the corrosion behavior in 0.6 M NaCl after short (1-hour) and long (30-day) exposure periods. The employed solidification methods allowed the production of samples with a wide range of secondary dendrite arm spacing (SDAS) while preserving Si and Fe-containing phases. The 0.5 wt.% Ni and Co additions led to the growth of the AlFeSi(Ni) and AlFeSi(Co) phases, but no binary AlNi nor AlCo intermetallic par-ticles have been generated. Potentiodynamic polarization studies at early exposure revealed an increase in the corrosion potential as the Ni was added for either fast or slow solidified samples. The electrochemical impedance spectroscopy at early exposure demonstrated that the Ni-modified alloy, on the other hand, was associated to smaller charge transfer resistances, in-dicating a reduction in corrosion resistance after short elapsed time into the electrolyte. Howev-er, 30-day immersion tests revealed much lower corrosion rate of the Ni-modified alloy than the other alloys, while the corrosion rates of the Co-modified and non-modified alloys were simi-lar. In the Ni-containing alloy, decreased corrosion rate under long-term corrosion process was attributed to the formation of a thick and dense alumina layer, effectively protecting the surface under such conditions. This work contributes to a better knowledge of the corrosion behavior of Ni- and Co-corrected Al industrial scrap compositions.