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Investigation on microstructure and localized corrosion behavior in the stir zone of dissimilar friction-stir-welded AA2024/7075 joint

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Abstract

Friction stir welding (FSW) is an effective welding technique to realize the joining of dissimilar aluminum alloys. The microstructural heterogeneities induced by FSW across the joints could have curial implication for the corrosion performance of the joints. In this research, the microstructure and localized corrosion behavior of shoulder interface zone (SIZ), vortex zone (VZ), bottom zone (BZ) and bottom interface zone (BIZ) in the stir zone (SZ) of dissimilar FSW AA2024/AA7075 joint was systematically investigated through detailed microstructural characterization and relevant corrosion tests. The results indicated that plentiful of Cu-rich constituent particles are formed on AA2024 side and the areas near the interface on both sides, and corrosion originates from these regions. Grain size has little influence on corrosion behavior of the SZ, while the local regions with higher stored energy are more sensitive and liable to corrosion. The sequence of mixing degree of materials in the four regions of the SZ is: BZ > VZ > SIZ > BIZ, which is in contrast to the order of corrosion rate. Galvanic corrosion is detected in the SIZ and BIZ, and sufficient mixing of materials significantly weakens the galvanic corrosion, resulting in higher corrosion resistance in the BZ.

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Acknowledgements

We greatly acknowledge the financial support of the “National Natural Science Foundation of China” (No. 51421001) and “Fundamental Research Funds for the Central Universities” (No. 2018CDJDCL0019). We also acknowledge the Electron Microscopy Center of Chongqing University for providing SEM and TEM test channel.

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Authors and Affiliations

  1. International Joint Laboratory for Light Alloys (MOE), College of Materials Science and Engineering, Chongqing University, Chongqing, 400044, People’s Republic of China

    Chenghang Zhang, Guangjie Huang, Yu Cao, Qilei Li, Yulong Zhu & Xinde Huang

  2. Shenyang National Laboratory for Materials Science, Chongqing University, Chongqing, 400044, People’s Republic of China

    Chenghang Zhang, Guangjie Huang, Yu Cao, Qilei Li, Yulong Zhu & Xinde Huang

  3. Department of Materials Science and Engineering, KTH Royal Institute of Technology, 100 44, Stockholm, Sweden

    Chenghang Zhang

  4. College of Materials Science and Engineering, Nanjing Tech University, Nanjing, 211816, People’s Republic of China

    Qing Liu

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  1. Chenghang Zhang
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Zhang, C., Huang, G., Cao, Y. et al. Investigation on microstructure and localized corrosion behavior in the stir zone of dissimilar friction-stir-welded AA2024/7075 joint. J Mater Sci 55, 15005–15032 (2020). https://doi.org/10.1007/s10853-020-05072-w

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