Microstructure and Corrosion Evolution of Aerospace AA2024 Al-Alloy Thin Wall Structure Produced Through WAAM

doi:10.11902/1005.4537.2021.149

Journal of Chinese Society for Corrosion and protection

2022, Vol. 42

Issue (4): 621-628 DOI: 10.11902/1005.4537.2021.149

Current Issue | Archive | Adv Search

Microstructure and Corrosion Evolution of Aerospace AA2024 Al-Alloy Thin Wall Structure Produced Through WAAM

ZHAO Haiyang¹^,², GAO Duolong¹^,², ZHANG Tong³, LV You³, ZHANG Yupeng³, ZHANG Xinxin³(

), SHI Xin¹^,², WEI Xiaojing¹^,², LIU Dongmei¹^,², DONG Zehua³

^1.SINOPEC Northwest Company of China Petroleum and Chemical Corporation, Urumqi 830011, China
^2.Key Laboratory of Enhanced Oil Recovery in Carbonate Fractured-vuggy Reservoirs, SINOPEC, Urumqi 830011, China
^3.School of Chemistry and Chemical Engineering, Huazhong University of Science and Technology, Wuhan 430074, China

Download:

HTML

PDF(18031KB)
Export: BibTeX | EndNote (RIS)

Abstract

The microstructure and corrosion behaviour of the wire arc additive manufactured (WAAM) thin wall structure of AA2024 Al-alloy are investigated by means of scanning electron microscope (SEM), transmission electron microscope (TEM) and energy dispersive X-ray spectrometer (EDX), as well as immersion test in 3.5%NaCl solution. Three distinctive areas, including melt pool zone (MPZ), melt pool border (MPB) and heat affected zone (HAZ), were formed in the WAAM structure. S-phase, θ-phase and α-phase are present in all three zones, which could exist individually or in cluster. Localized corrosion tends to initiate at MPB rather than HAZ and MPZ, which is closely associated with the de-alloying behaviour of intermetallic (IM) particles.

Key words: intermetallic additive manufacturing de-alloying AA2024 Al-alloy localized corrosion

Received: 29 June 2021

ZTFLH:

TG172.5

Fund: Hubei Provincial Natural Science Foundation of China(2020CFB295);Aeronautical Science Foundation of China(2020Z008079004);National Natural Science Foundation of China(52001128)

Corresponding Authors: ZHANG Xinxin E-mail: xinxinzhang@hust.edu.cn

About author: ZHANG Xinxin, E-mail: xinxinzhang@hust.edu.cn

	Service

	E-mail this article
	Add to citation manager
	E-mail Alert
	RSS
	（）
	Articles by authors
	Haiyang ZHAO
	Duolong GAO
	Tong ZHANG
	You LV
	Yupeng ZHANG
	Xinxin ZHANG
	Xin SHI
	Xiaojing WEI
	Dongmei LIU
	Zehua DONG

Cite this article:

ZHAO Haiyang, GAO Duolong, ZHANG Tong, LV You, ZHANG Yupeng, ZHANG Xinxin, SHI Xin, WEI Xiaojing, LIU Dongmei, DONG Zehua. Microstructure and Corrosion Evolution of Aerospace AA2024 Al-Alloy Thin Wall Structure Produced Through WAAM. Journal of Chinese Society for Corrosion and protection, 2022, 42(4): 621-628.

URL:

https://www.jcscp.org/EN/10.11902/1005.4537.2021.149 OR https://www.jcscp.org/EN/Y2022/V42/I4/621

Fig.1 Schematic diagram of WAAM process

Fig.2 Grain structure of the WAAM thin wall structure after anodizing in Barker's agent

Fig.3 SEM micrographs of the WAAM thin wall structure: (a) general view, (b) MPZ, (c) PMB, (d) HAZ

Fig.4 EDX spectra corresponding to S phase (a), θ phase (c) and α phase (e) and SEM micrographs (corresponding to surface A in Fig.1) along with the corresponding EDX maps from MPZ (b), MPB (d) and HAZ (f) in the thin wall structure

Fig.5 HAADF micrograph (a) and its EDX maps (b) of the multi-phase intermetallics in MPB

Fig.6 Photographs of as-manufactured WAAM thin wall structure after 30 min (a) and 10 h (b) immersion

Fig.7 SEM micrographs of the WAAM thin wall structure after 30 min immersion: surface morphology (a), local magnification of the MPB region (b), cross-section morphology (c) and after 10 h immersion: surface morphology (d), surface morphology with corrosion products removed (e)

Fig.8 HAADF micrograph of the cross section at a typical localized corrosion site in MPB (a), framed area in Fig.8a at increased magnification (b), EDX spectrum (c), high resolution TEM micrograph (d) and electron diffraction of a typical nanoparticle in Fig.8b (e)

1	Ding Q M, Qin Y X, Cui Y Y. Galvanic corrosion of aircraft components in atmospheric environment [J]. J. Chin. Soc. Corros. Prot., 2020, 40: 455
	丁清苗, 秦永祥, 崔艳雨. 大气环境中飞机构件的电偶腐蚀研究 [J]. 中国腐蚀与防护学报, 2020, 40: 455
2	Rioja R J, Liu J. The evolution of Al-Li base products for aerospace and space applications [J]. Metall. Mater. Trans., 2012, 43A: 3325
3	Gong S L, Suo H B, Li H X. Development and application of metal Additive manufacturing technology [J]. Aeronaut. Manuf. Technol., 2013, (13): 66
	巩水利, 锁红波, 李怀学. 金属增材制造技术在航空领域的发展与应用 [J]. 航空制造技术, 2013, (13): 66
4	Yang Q, Lu Z L, Huang F X, et al. Research on status and development trend of laser additive manufacturing [J]. Aeronaut. Manuf. Technol., 2016, (12): 26
	杨强, 鲁中良, 黄福享等. 激光增材制造技术的研究现状及发展趋势 [J]. 航空制造技术, 2016, (12): 26
5	Karabin L M, Bray G H, Rioja R J, et al. Al-Li-Cu-Mg-(Ag) products for lower wing skin applications [A]. Proceedings of the 13th International Conference on Aluminum Alloys [C]. Cham, 2012: 529
6	Lin X, Huang W D. High performance metal additive manufacturing technology applied in aviation field [J]. Mater. China, 2015, 34: 684
	林鑫, 黄卫东. 应用于航空领域的金属高性能增材制造技术 [J]. 中国材料进展, 2015, 34: 684
7	Williams S W, Martina F, Addison A C, et al. Wire+arc additive manufacturing [J]. Mater. Sci. Technol., 2016, 32: 641 doi: 10.1179/1743284715Y.0000000073
8	Frazier W E. Metal additive manufacturing: a review [J]. J. Mater. Eng. Perform., 2014, 23: 1917 doi: 10.1007/s11665-014-0958-z
9	Gong X B, Anderson T, Chou K, et al. Review on powder-based electron beam additive manufacturing technology [A]. ASME/ISCIE 2012 International Symposium on Flexible Automation [C]. St. Louis, 2012: 507
10	Zhang X X, Lv Y, Tan S H, et al. Microstructure and corrosion be/haviour of wire arc additive manufactured AA2024 alloy thin wall structure [J]. Corros. Sci., 2021, 186: 109453 doi: 10.1016/j.corsci.2021.109453
11	Vimal K E K, Srinivas M N, Rajak S. Wire arc additive manufacturing of aluminium alloys: a review [J]. Mater. Today: Proc., 2021, 41: 1139
12	Wang F D, Williams S, Colegrove P, et al. Microstructure and mechanical properties of wire and arc additive manufactured Ti-6Al-4V [J]. Metall. Mater. Trans., 2013, 44A: 968
13	Qiao J S, Xia Z H, Liu L B, et al. Corrosion resistance of aluminum-magnesium bimetal composite material prepared by isothermal indirect extrusion [J]. J. Chin. Soc. Corros. Prot., 2021, 41: 255
	乔及森, 夏宗辉, 刘立博等. 铝镁双金属反向等温包覆挤压棒材耐腐蚀性能 [J]. 中国腐蚀与防护学报, 2021, 41: 255
14	Bartkowiak K, Ullrich S, Frick T, et al. New developments of laser processing aluminium alloys via additive manufacturing technique [J]. Phys. Proced., 2011, 12: 393 doi: 10.1016/j.phpro.2011.03.050
15	Yang X Y, Li Y, Zhao P K, et al. Research status and challenges of wire and arc additive manufacturing in material preparation [J]. Weld. Join., 2018, (8): 14
	杨笑宇, 李言, 赵鹏康等. 电弧增材制造技术在材料制备中的研究现状及挑战 [J]. 焊接, 2018, (8): 14
16	Moran T P, Warner D H, Phan N. Scan-by-scan part-scale thermal modelling for defect prediction in metal additive manufacturing [J]. Addit. Manuf., 2021, 37: 101667
17	Plessis A D, Yadroitsava I, Yadroitsev I. Effects of defects on mechanical properties in metal additive manufacturing: a review focusing on X-ray tomography insights [J]. Mater. Design, 2019, 187: 108385
18	Geng R W, Du J, Wei Z Y, et al. Multiscale modelling of microstructure, micro-segregation, and local mechanical properties of Al-Cu alloys in wire and arc additive manufacturing [J]. Addit. Manuf., 2020, 36: 1017
19	Zhang X X, Liu B, Zhou X R, et al. Laser welding introduced segregation and its influence on the corrosion behaviour of Al-Cu-Li alloy [J]. Corros. Sci., 2018, 135: 177 doi: 10.1016/j.corsci.2018.02.044
20	Rafieazad M, Mohammadi M, Nasiri A M. On microstructure and early stage corrosion performance of heat treated direct metal laser sintered AlSi10Mg [J]. Addit. Manuf., 2019, 28: 107 doi: 10.1016/j.addma.2019.04.023
21	Rubben T, Revilla R I, De Graeve I. Influence of heat treatments on the corrosion mechanism of additive manufactured AlSi10Mg [J]. Corros. Sci., 2019, 147: 406 doi: 10.1016/j.corsci.2018.11.038
22	Gharbi O, Jiang D, Feenstra D R, et al. On the corrosion of additively manufactured aluminium alloy AA2024 prepared by selective laser melting [J]. Corros. Sci., 2018, 143: 93 doi: 10.1016/j.corsci.2018.08.019
23	Fathi P, Mohammadi M, Duan X L, et al. A comparative study on corrosion and microstructure of direct metal laser sintered AlSi10Mg_200C and die cast A360.1 aluminum [J]. J. Mater. Process. Tech., 2018, 259: 1 doi: 10.1016/j.jmatprotec.2018.04.013
24	Wang P, Zhang Z D, Song G, et al. Analysis of laser-arc composite additive manufacturing process for aluminum alloy [J]. Weld. Technol., 2016, 45(10): 10
	王鹏, 张兆栋, 宋刚等. 铝合金激光-电弧复合增材制造工艺分析 [J]. 焊接技术, 2016, 45(10): 10
25	Fang X W, Zhang L J, Chen G P, et al. Microstructure evolution of wire-arc additively manufactured 2319 aluminum alloy with interlayer hammering [J]. Mater. Sci. Eng., 2021, 800A: 140168
26	Yoder J K, Griffiths R J, Yu H Z. Deformation-based additive manufacturing of 7075 aluminum with wrought-like mechanical properties [J]. Mater. Design, 2021, 198: 109288
27	Hashimoto T, Zhang X, Zhou X, et al. Investigation of dealloying of S phase (Al₂CuMg) in AA 2024-T3 aluminium alloy using high resolution 2D and 3D electron imaging [J]. Corros. Sci., 2016, 103: 157 doi: 10.1016/j.corsci.2015.11.013
28	Zhang X, Hashimoto T, Lindsay J, et al. Investigation of the de-alloying behaviour of θ-phase (Al₂Cu) in AA2024-T351 aluminium alloy [J]. Corros. Sci., 2016, 108: 85 doi: 10.1016/j.corsci.2016.03.003
29	Erlebacher J, Aziz M J, Karma A, et al. Evolution of nanoporosity in dealloying [J]. Nature, 2001, 410: 450 doi: 10.1038/35068529
30	Buchheit R G, Grant R P, Hlava P F, et al. Local dissolution phenomena associated with S phase (Al₂CuMg) particles in aluminum alloy 2024-T3 [J]. J. Electrochem. Soc., 1997, 144: 2621 doi: 10.1149/1.1837874
31	Boag A, Taylor R J, Muster T H, et al. Stable pit formation on AA2024-T3 in a NaCl environment [J]. Corros. Sci., 2010, 52: 90 doi: 10.1016/j.corsci.2009.08.043
32	Boag A, Hughes A E, Glenn A M, et al. Corrosion of AA2024-T3 part I: localised corrosion of isolated IM particles [J]. Corros. Sci., 2011, 53: 17 doi: 10.1016/j.corsci.2010.09.009
33	Hashimoto T, Curioni M, Zhou X, et al. Investigation of dealloying by ultra-high-resolution nanotomography [J]. Surf. Interface Anal., 2013, 45: 1548 doi: 10.1002/sia.5176
34	Zhou X, Luo C, Hashimoto T, et al. Study of localized corrosion in AA2024 aluminium alloy using electron tomography [J]. Corros. Sci., 2012, 58: 299 doi: 10.1016/j.corsci.2012.02.001
35	Zhang X X, Zhou X R, Hashimoto T, et al. Localized corrosion in AA2024-T351 aluminium alloy: transition from intergranular corrosion to crystallographic pitting [J]. Mater. Charact., 2017, 130: 230 doi: 10.1016/j.matchar.2017.06.022
36	Szklarska-Smialowska Z. Pitting corrosion of aluminum [J]. Corros. Sci., 1999, 41: 1743 doi: 10.1016/S0010-938X(99)00012-8
37	Zhang X X, Jiao Y B, Yu Y, et al. Intergranular corrosion in AA2024-T3 aluminium alloy: the influence of stored energy and prediction [J]. Corros. Sci., 2019, 155: 1 doi: 10.1016/j.corsci.2019.04.031

[1]	JIA Yizheng, ZHAO Mingjun, CHENG Shijing, WANG Baojie, WANG Shuo, SHENG Liyuan, XU Daokui. Corrosion Behavior of Mg-Zn-Y-Nd Alloy in Simulated Body Fluid[J]. 中国腐蚀与防护学报, 2019, 39(6): 463-468.
[2]	Baojie WANG,Jiyu LUAN,Shidong WANG,Daokui XU. Research Progress on Stress Corrosion Cracking Behavior of Magnesium Alloys[J]. 中国腐蚀与防护学报, 2019, 39(2): 89-95.
[3]	Chao FENG, Bicao PENG, Yi XIE, Jun WANG, Minghuan LI, Tangqing WU, Fucheng YIN. Corrosion Behavior of T91 Steel by Salt Spray with 0.1%NaHSO₃ Solution[J]. 中国腐蚀与防护学报, 2017, 37(6): 583-589.
[4]	Penghui ZHANG, Kun PANG, Kangkang DING, Xiangfeng KONG, Xin PENG. Research Progress of Scanning Vibrating Electrode Technique in Field of Corrosion[J]. 中国腐蚀与防护学报, 2017, 37(4): 315-321.
[5]	Yao CHEN,Honghua ZHANG,Ganlan YANG,Junhuai XIANG. Influence of Heat Treatment on Microstructure of Composite Coatings of FeAl-Cr₃C₂[J]. 中国腐蚀与防护学报, 2017, 37(1): 58-62.
[6]	Shuzhen ZHAO,Lining XU,Juanjuan DOU,Wei CHANG,Minxu LU. Influence of Acetic Acid on Top Localized Corrosion of X70 Steel Pipeline in CO₂ Containing Wet Gas[J]. 中国腐蚀与防护学报, 2016, 36(3): 231-237.
[7]	Xiao TANG,Chuntao SHI,Guang CAO,Yan LI. Effect of Coastal Soil Environment on Localized Corrosion for Oil and Gas Pipelines[J]. 中国腐蚀与防护学报, 2016, 36(3): 191-196.
[8]	LIU Yu,LI Yan. Research Progress of CO₂ Corrosion of Internal Gas Pipeline Steel[J]. 中国腐蚀与防护学报, 2013, 33(1): 1-9.
[9]	Shizhen Zhang; Jianting Guo; Weili Ren; Wenlong Zhou. EFFECTS OF RARE EARTH ELEMENTS ON HIGH TEMPERATURE OXIDATION RESISTANCE OF NiAl/CrMo(Hf) ALLOY[J]. 中国腐蚀与防护学报, 2005, 25(2): 110-114 .
[10]	Fanjun Meng. Oxidation Behavior of Fe-Al Coatings Produced by High Velocity Arc Spraying at 800℃[J]. 中国腐蚀与防护学报, 2004, 24(6): 368-371 .
[11]	. Chemical Changes Within Occluded Cell for Localized Corrosion of Iron Artifacts in Chloride Solution[J]. 中国腐蚀与防护学报, 2004, 24(6): 364-367 .
[12]	Yong Shen. High-Temperature Oxidation Resistance of High-Nb TiAl-Based Alloy[J]. 中国腐蚀与防护学报, 2004, 24(4): 203-207 .
[13]	. Study on High Temperature Oxidation of Al60Mn13Ti25V2 Intermetallic[J]. 中国腐蚀与防护学报, 2004, 24(3): 129-134 .
[14]	Dayang Liu; Kaijin Wei; Wenjun Li. INFLUENCE OF ENVIRONMENTAL FACTORS IN YULIN AREA OFTHE SOUTH CHINA SEA ON LOCALIZED CORROSION OF STEELS[J]. 中国腐蚀与防护学报, 2003, 23(4): 211-216 .
[15]	Chunchun Xv; Xiaomei Wu. THE INFLUENCE OF THE LOCAL CORROSION OF 304 STAINLESS STEEL BY ANIONS[J]. 中国腐蚀与防护学报, 2003, 23(3): 129-133 .

No Suggested Reading articles found!

Viewed

Full text

Abstract

Cited

Shared

Discussed