Loïc Lacroix

Localized Approach to Galvanic Coupling in an Aluminum–Magnesium System

The corrosion behavior of a pure aluminum/pure magnesium couple in a weakly conductive sodium sulfate solution was investigated. Potential and current distributions on the surface of the model couple at the beginning of immersion were obtained by solving the Laplace equation using a finite element method algorithm. Magnesium acted as the anode of the system while oxygen and water were reduced on aluminum. Calculations predicted a large current peak at the Al/Mg interface related to a local increase in both Mg dissolution and oxygen and water reduction on aluminum, leading to a local pH increase. Optical and scanning electron microscope observations confirmed the strong dissolution of magnesium concomitantly with depassivation of aluminum at the Al/Mg interface. Local electrochemical impedance spectroscopy showed the detrimental effects of the galvanic coupling both on aluminum and magnesium.

Study of the Influence of the Artificial Ageing Temperature on the AA2024 Alloy Microstructure

For the last 30 years, AA2024 aluminum alloy was very used as structural material in the aerospace industry due to its low density and good mechanical strength. The phenomenon of precipitation hardening in aluminum alloys takes place at relatively low temperature and induces the precipitation of intermetallic particles composed of the main alloying elements i.e., copper and magnesium. The fundamental stage of the age-hardening process consists in the acceleration of the decomposition phenomenon of the supersaturated solid solution, resulting in the coarse intermetallic particle precipitation; stage where the mechanical properties reaches the maximum values, but at the cost of a low corrosion resistance. In this paper, the AA2024 alloy microstructure was studied during the over-ageing process. The over-ageing treatment (T7) is supposed to stabilize the microstructure and the mechanical properties to improve the corrosion resistance. The over-ageing treatment consists in a solution treatment at 495±5°C for 1 hour, quenched into cold water and artificial aged. Three different artificial ageing temperatures were studied: 150°C, 175°C and 190°C. The mechanical properties modifications were followed by Vickers macrohardness measurements. The treatment duration for each temperature (36 days for 150°C, 50 hrs for 175°C and 24 hrs for 190°C) was determined by a given macrohardness reduction. To characterize the over-aged AA2024 alloy microstructure, a statistical analysis of the surface fraction and surface density of intermetallic particles was made. The intermetallic particle dimension distribution, depending on the over-ageing temperature, was also observed. To do so, scanning electron microscope observations were carried out and image analyses were performed from backscattered electron images.

Application of Kelvin probe Force Microscopy (KFM) to evidence localized corrosion of over-aged aeronautical 2024 aluminum alloy

The 2xxx serie aluminum alloys are characterized by good mechanical performances and low density, however they are susceptible to different forms of localized corrosion: pitting corrosion, intergranular corrosion and stress corrosion cracking. The 2024-T351 aluminum alloy is used in the aircraft industry for numerous applications such as fuselage and door skin. Corrosion damage of the material is also very detrimental for the structural integrity of the aircraft. The presence of coarse intermetallic particles, with a heterogeneous size distribution was found to be responsible for the 2024 susceptibility to localized corrosion. These particles are generally the cause of initiation sites. Presence of micro-defects in the oxide film upon coarse intermetallic particles and the galvanic coupling with the matrix contribute to the development of pitting corrosion. The over-ageing treatment (T7) is supposed to stabilize the microstructure and the mechanical properties to improve the corrosion resistance. The 2024 alloy microstructure after the T7 heat treatment remains very complex. The 2024 alloy corrosion behavior was studied in the over-ageing state for three different temperatures (150, 175 and 190 °C). During the corrosion tests in chloride-containing environment, the behavior of coarse intermetallic particles was found to be different. Thus, the 2024 samples suffer a gradual attack upon S-Al2CuMg particles and finally Al (Cu,Mn,Fe,Si) particles. The corrosion damage was studied by Atomic Force Microscopy (AFM) and Kelvin probe Force Microscopy (KFM). This technique allows simultaneous topographical and electric potential mapping to be obtained. This latest potential was shown to be correlated to the corrosion potential of the 2024 alloy. This study focuses on the variation of the KFM potential of the coarse intermetallic particles and the matrix for the over-ageing conditions (T7). Observations using optical microscope and AFM were also performed to obtain the corrosion rate for each condition. The corrosion rate was correlated to the chemical composition variation of the particles obtained by scanning electron microscope observations and EDS analyses.