The Corrosion Behaviour of a Hypereutectic Al-Si Alloy Obtained by Spray Forming in Acid, Neutral and Alkaline Solutions

Abstract

Al-Si hypereutectic alloys produced by spray forming represent an important technological development for application in the aeronautical and automotive industries. Due to some special properties these alloys find application as cylinder liners, mainly due to their high strength and wear resistance. Much research has been carried out to evaluate the mechanical properties of these alloys but the literature on their corrosion performance is still very scarce. In this study, the corrosion behaviour of a spray formed Al-Si-Cu hypereutectic alloy was investigated by electrochemical impedance spectroscopy (EIS) in acid (pH 3.3), neutral (pH 7) and alkaline (pH 11) solutions. Intense localized attack occurred in the acid electrolyte and the impedance decreased with time of immersion. In the neutral medium, the alloy was passivated but localized attack also occurred on weak areas of the passive film. In the alkaline medium, precipitation of corrosion products occurred during the first hours of immersion causing the increase of impedance but thickening of this layer led to cracks growth with time and, consequently, to the exposure of metallic substrate, resulting in the decrease in impedance for longer periods.