Corrosion Resistance of Aluminum-Copper Alloys with Different Grain Structures

Electrochemical studies and microstructure analysis of directionally solidified hypoeutectic and eutectic aluminum-copper alloys were performed. Optical and scanning electron microscopy studies of corroded specimens with columnar and equiaxed microstructures in 0.1 M, 0.5 M, and 1 M NaCl solutions were conducted. Low-rate potential scanning and alternating current (AC) electrode impedance measurements were conducted to study the corrosion resistance of four aluminum-copper alloys. The concentration of Cu in the alloys proved to be a key factor in the corrosion resistance of the Al-Cu alloys, which controlled the fraction of alpha and theta phases and the morphological distribution of these phases. The addition of Cu provides cathodic sites that increase adjacent anodic activity and higher corrosion susceptibility of the Al-Cu alloys, as compared with pure Al. Arise in the Cu amount that is linked to an increased concentration of the Al2Cu intermetallic or theta phase results in a higher susceptibility to corrosion for the studied alloys. A microstructural morphology related to a decreased area of contact between the alpha-phase and the Al2Cu intermetallic phase enhances the corrosion resistance of the Al-Cu alloys. For the Al-1wt.%Cu alloy increasing the content of Cl- produces a beneficial result related to a more resistive passive film. For the rest of the studied alloys with nobler corrosion potentials, the increase in Cl- results in a decrease in their corrosion resistance.

Automated summary

Electrochemical studies and microstructure analysis were conducted on directionally solidified hypoeutectic and eutectic aluminum-copper alloys. The addition of copper in the alloys was found to increase the corrosion susceptibility due to the formation of cathodic sites, while an increase in the concentration of Al2Cu intermetallic compound resulted in higher corrosion susceptibility. The morphology of the microstructure played a crucial role in enhancing the corrosion resistance of the Al-Cu alloys.