Microstructure, hardness and corrosion behaviour of friction-stir processed AA5083

Abstract

The purpose of this study is to refine the microstructure and improve the corrosion behaviour of aluminium alloy AA5083 by subjecting it to friction stir processing (FSP).,FSP trials are conducted as per central composite design, by varying tool rotation speed, tool traverse speed and shoulder diameter at three levels. The microstructure is examined and the hardness is measured for both the base material and the processed workpieces. The corrosion behaviour of the base material and processed workpieces is studied using potentiodynamic polarization technique for three different testing temperatures, and the corrosion current and corrosion rate are calculated.,The results reveal that FSP refined the grains, dispersed secondary phases, increased the hardness and improved the corrosion resistance of most of the friction stir processed specimens than the base material at all the three testing temperatures. Grain refinement and fine dispersion of s phase improves the hardness and corrosion resistance of most of the FSPed specimens. However partial dissolution of s phase decreases the hardness in some of the specimens. Most of the FSPed specimens displayed more positive potential than the base material at all the testing temperatures representing a higher nobility than the base material, as a result of fine dispersion of secondary phase particles in the matrix. Large pits formed on the surface of the base specimen indicating a higher corrosion rate at all three testing temperatures. The SEM image of FSPed specimens reveals the occurrence of very few pits and minimal corrosion products on the surface, which indicates lower corrosion rate.,The corrosion mechanism of the friction stir-processed AA5083 specimens is found to be a combination of activation and concentration polarization.