Effect of aging on yield stress and corrosion resistance of die cast magnesium alloy

Corrosion resistance is an important property that could be affected by the ageing process. In order to investigate whether aging affects the corrosion resistance, corrosion rate and yield strength of diecast magnesium alloy AZ91D were measured and analysed after ageing. It was found that the dependence of the corrosion rate on ageing time can be ascribed to the changes in microstructure of the alloy and chemical composition of its matrix. Precipitation of the P phase (Mg17Al12) occurred along the grain boundaries during the initial ageing stages, resulting in a decreasing corrosion rate and an inceasing yield strength. In the later stages, the decreasing aluminium content in the alpha matrix made it more active, causing an increase in the corrosion rate. The decrease in aluminium content in the matrix also leads to a decrease in yield strength.

Simulation of galvanic corrosion of magnesium coupled to a steel fastener in NaCl solution

The galvanic corrosion of magnesium alloy AZ91D coupled to a steel fastener was studied using a boundary element method (BEM) model and experimental measurements. The BEM model used the measured polarization curves as boundary conditions. The experimental program involved measuring the total corrosion rate as a function of distance from the interface of the magnesium in the form of a sheet containing a mild steel circular insert (5 to 30 mm in diameter). The measured total corrosion rate was interpreted as due to galvanic corrosion plus self corrosion. For a typical case, the self corrosion was estimated typically to be similar to 230 mm/y for an area surrounding the interface and to a distance of about I cm from the interface. Scanning Kelvin Probe Force Microscopy (SKPFM) revealed microgalvanic cells with potential differences of approximately 100 mV across the AZ91D surface. These microgalvanic cells may influence the relative contributions of galvanic and self corrosion to the total corrosion of AZ91D.

Boundary element method predictions of the influence of the electrolyte on the galvanic corrosion of AZ91D coupled to steel

This research investigated the galvanic corrosion of the magnesium alloy AZ91D coupled to steel. The galvanic current distribution was measured in 5% NaCl solution, corrosive water and an auto coolant. The experimental measurements were compared with predictions from a Boundary Element Method (BEM) model. The boundary condition, required as an input into the BEM model, needs to be a polarization curve that accurately reflects the corrosion process. Provided that the polarization curve does reflect steady state, the BEM model is expected to be able to reflect steady state galvanic corrosion.

Corrosion of magnesium alloys in commercial engine coolants

A number of magnesium alloys show promise as engine block materials. However, a critical issue for the automotive industry is corrosion of the engine block by the coolant and this could limit the use of magnesium engine blocks. This work assesses the corrosion performance of conventional magnesium alloy AZ91D and a recently developed engine block magnesium alloy AM-SC1 in several commercial coolants. Immersion testing, hydrogen evolution measurement, galvanic current monitoring and the standard ASTM D1384 test were employed to reveal the corrosion performance of the magnesium alloys subjected to the coolants. The results show that the tested commercial coolants are corrosive to the magnesium alloys in terms of general and galvanic corrosion. The two magnesium alloys exhibited slightly different corrosion resistance to the coolants with AZ91D being more corrosion resistant than AM-SC1. The corrosivity varied from coolant to coolant. Generally speaking. an oraganic-acid based long life coolant was less corrosive to the magnesium alloys than a traditional coolant. Among the studied commercial coolants. Toyota long, life coolant appeared to be the most promising one. In addition. it was found that potassium fluoride effectively inhibited corrosion of the magnesium alloys in the studied commercial coolants. Both general and galvanic corrosion rates were significantly decreased by addition of KF, and there were no evident side effects on the other engine block materials, such as copper, solder. brass. steel and aluminium alloys, in terms of their corrosion performance. The ASTM D 1384 test further confirmed these results and suggested that Toyota long life coolant with 1%wt KF addition is a promising coolant for magnesium engine blocks.

Atom probe field ion microscope measurements of carbon segregation at an a:a grain boundary and service failures by intergranular stress corrosion cracking

This work reports on a critical measurement to understand the intergranular stress corrosion cracking (IGSCC) of pipeline steels: the atom probe field ion microscope (APFIM) measurement of the carbon concentration at a grain boundary (GB). The APFIM measurement was related to the microstructure and to IGSCC observations. The APFIM indicated that the GB carbon concentration of X70 was similar to 10 at% or less, which correlated with a high resistance to IGSCC for X70. (C) 2005 Elsevier Ltd. All rights reserved.

The Corrosion Performance of Magnesium Alloy AM-SC1 in Automotive Engine Block Applications

The magnesium alloy AM-SC1 has been developed as a creep-resistant automotive engine block material. This paper outlines its corrosion performance under laboratory test conditions, considering corrosion on both the external and internal surfaces. This study found that AM-SC1 has a corrosion performance comparable to AZ91 when subjected to an aggressive salt-spray environment or in galvanic-coupling environments. This article further demonstrates that, with the appropriate selection of a commercially available engine coolant, the internal corrosion of AM-SC1 can be maintained at a tolerable level. In addition, internal corrosion resistance can be significantly improved by the addition of fluorides to the coolant solution. It is concluded that AM-SC1 can be successfully used in an engine environment provided that some simple corrosion-prevention strategies are adopted.

Improved corrosion resistance of AZ91D magnesium alloy by an aluminium-alloyed coating

An aluminum-alloyed coating was applied onto the surface of magnesium alloy AZ91D. The coating formed in aluminium powder at 420 degrees C is rich in the beta (Mg17Al12) phase. Polarisation curve, AC impedance, salt immersion and salt spray were carried out to investigate the corrosion behaviour and assess the corrosion performance of the coated magnesium alloy. It was found that a coated AZ91D specimen was much more corrosion resistant and harder than an uncoated one. The improved corrosion resistance was mainly ascribed to the high volume fraction of beta phase in the coating. (c) 2004 Elsevier B.V. All rights reserved.

Influence of anodising current on the corrosion resistance of anodised AZ91D magnesium alloy

The thickness, chemical composition and microstructure of anodised coatings formed on magnesium alloy AZ91D at various anodising current densities were measured. It was found that all these parameters could be affected by anodising current density, and hence the coatings formed at different anodising current densities had different corrosion resistances. This suggests that the corrosion performance of an anodised coating could be improved if a properly designed current waveform is used for anodising. In addition, based on the experimental results, some physical, chemical and electrochemical reactions involved in the anodising process were proposed to explain the anodising behaviour in this paper. (c) 2005 Elsevier Ltd. All rights reserved.

Corrosion resistance of anodised single-phase Mg alloys

This work studied the effect of the impurity iron and the alloying elements aluminium and zinc in single-phase substrate magnesium alloys on the corrosion resistance of the alloys after anodisation. It was found that increasing zinc content (0-2%) led to increased corrosion resistance of an anodised single-phase Mg-Zn alloy. The addition of Al lowered the corrosion resistance of an anodised commercial purity Mg-Al single-phase alloy, whereas the same addition was found to be beneficial to the corrosion resistance of an anodised high purity Mg-Al single-phase alloy. Heat-treatment made the substrate Mg-Al and Mg-Zn alloys more uniform and hence improved the corrosion resistance of the alloys after anodisation. The detrimental effect of iron impurity on corrosion performance of the unanodised substrate single-phase magnesium alloys was inherited by the anodised alloys. The corrosion resistance of the anodised Mg alloys was found to be closely correlated with the corrosion performance of the unanodised as-cast Mg alloys. (c) 2005 Elsevier B.V. All rights reserved.

Influence of geometry on galvanic corrosion of AZ91D coupled to steel

The influence of geometric factors on the galvanic current density distribution for AZ91D coupled to steel was investigated using experimental measurements and a BEM model. The geometric factors were area ratio of anode/cathode, insulation distance between anode and cathode, depth of solution film covering the galvanic couple and the manner of interaction caused by two independent interacting galvanic couples. The galvanic current density distribution calculated from the BEM model was in good agreement with the experimental measurements. The galvanic current density distribution caused by the interaction of two independent galvanic couples can be reasonably predicted as the linear addition of the galvanic current density caused by each individual galvanic couple. (c) 2005 Elsevier Ltd. All rights reserved.

Erosion-corrosion of mild steel in hot caustic. Part I: NaOH solution

A novel apparatus, high-pressure/high-temperature nickel flow loop, was constructed to study the effect of the flow on the rate of erosion-corrosion of mild steel in hot caustic. It has been successfully used to measure the corrosion rate of 1020 steel in 2.75 M NaOH solution at a temperature of 160 degrees C and velocities of 0.32 and 2.5 m/s. In situ electrochemical methods were used to measure the corrosion rate such as the potentiodynamic sweep, the polarization resistance method, and electrochemical impedance spectroscopy (EIS). Also used were the weight-loss method and scanning electron microscopy (SEM). Eight electrodes/coupons were used to monitor the metal loss rate, four were placed at the low velocity section, while the other four were placed in the high velocity section. The first three coupons in each section were placed within the disturbed flow region, while the fourth was placed in a fully developed flow region. The corrosion rate of the coupons in the high velocity section was generally higher than that of the coupons in the low velocity section. One coupon in the disturbed flow region had a significantly higher corrosion rate than the others. (c) 2005 Elsevier Ltd. All rights reserved.

Anodizing treatments for magnesium alloys and their effecton corrosion resistance in various environments

This paper reviews various aspects of anodizing of magnesium alloys, such as the basics, processes, properties and applications. It systematically summarises the existing fundamental studies and technical developments of anodizing of magnesium alloys, and concludes that new anodizing processes based on electrolytic plasma anodizing that convert the surface of a magnesium alloy into a hard ceramic coating in an electrolytic bath using high energy electric discharges can offer improved wear and corrosion resistance. These new anodized coatings are often claimed to perform better than the traditional ones obtained through older anodizing processes, such as DOW17 or HAE. The new anodizing techniques are chromate free and hence environment friendly. It is expected that more cost-effective, environment-friendly and non-toxic anodizing techniques will be developed and applied to magnesium alloy components in the future.

Corrosion behaviour of pure magnesium in a simulated body fluid

The corrosion behaviour of pure magnesium in Hank's simulated body fluid (SBF) was investigated. It was found that the polarization of Mg in the SBF solution was similar to that in a NaCl aqueous solution. However, AC impedance analysis suggested that the detailed dissolution steps involved in the corrosion of Mg in the SBF could be different in terms of their rates or contributions to corrosion damage of Mg. Moreover, the corrosion rate of Mg in the SBF solution was found to be increasing with time and significant hydrogen evolution and alkalization of the SBF solution resulting from corrosion of Mg were measured in the study. The results suggested that after some proper measures are taken to retard corrosion reaction, Mg can be successfully employed as a degradable and absorbable implant material.

Erosion-corrosion of mild steel in hot caustic. Part II: The effect of acid cleaning

Corrosion rates of 1020 steel in 2.75 M NaOH solution at a temperature of 160 degrees C and velocities of 0.32 and 2.5 m/s were studied. The focus was on the effect of the acid cleaning which was performed by using strong, inhibited sulphuric acid in between the exposures to caustic. In situ electrochemical methods were used to measure the corrosion rate such as the potentiodynamic sweep and the polarization resistance method. Also used were the weight-loss method and scanning electron microscopy (SEM). Eight electrodes/coupons were used to monitor the metal loss rate, four were placed at the low velocity section, while the other four were placed in the high velocity section of a high temperature flow. The first three coupons in each section were placed within the disturbed flow region, while the fourth was placed in a fully developed flow region. During the exposure of mild steel to the inhibited acid, following the first caustic period, the corrosion rate increased significantly to between 3 and 10mm/y with a few electrodes experiencing as high as 50 mm/y. The second caustic period following the acidic period typically started with very high corrosion rates (20-80 mm/y). The length of this corrosion period was typically 2-3 h with a few exceptions when the high corrosion period lasted 7-10 h. Following the very high corrosion rates experienced at the beginning of the second caustic period, the corrosion rates were reduced sharply (as the corrosion potential increased) to nearly the same levels as those observed during the passive part of the first caustic period. (c) 2005 Elsevier Ltd. All rights reserved.

Stress corrosion cracking and hydrogen diffusion in magnesium

Evaluation of recent data for hydrogen (H) diffusion in magnesium (Mg) yielded a new equation for the diffusion coefficient of H in Mg. This indicates that there can be significant H transport ahead of a stress corrosion crack in Mg at ambient temperature and that H may be involved in the mechanism of stress corrosion cracking in Mg.