Exfoliation corrosion susceptibility on friction stir welded aluminium 6061/Cr2O3 composite

Abstract

Abstract The current study investigates the exfoliation corrosion behavior of friction stir welded aluminum composite. The stir casting method was employed to fabricate chromium oxide (2 and 4% wt) reinforced Al 6061 composites. The fabricated composite samples are friction stir welded with two process parameters. The solution immersion tests were performed for two intervals per the ASTM G34 (24 h, 48 h), and the weight loss method was employed. The corrosion sample is analyzed by optical microscope FESEM and surface roughness. The gelatinous corrosion product formed over the surface can apply pressure over the grains resulting in the formation of pits. The intergranular corrosion (IGC) is formed by continuous penetration of the solution and the pits. The grains suffering from IGC are more susceptible to pit. The weight-loss method is not sufficient to predict the damage induced by the exco solution. Evaluating the pit depth can help to know the severity of corrosion. The measurement of the pit is difficult due to its irregular nature. The surface roughness instrument is used, and the damage is represented in average roughness (Ra) and average depth (Rz). The exposure duration and welding parameters play a significant role in corrosion. More material is lost at higher process parameters and extended hours of the test, forming higher surface deterioration.