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<p>The microstructural evolution and corrosion behavior of AA2024 aluminum matrix composites reinforced with varying weight percentages (2, 4, 6, and 8 wt.%) of brass particles, processed by Friction Stir Processing (FSP) are investigated. The microstructural characterization by optical microscopy, scanning electron microscopy (SEM), and XRD reveals that 4 wt.% brass provides the most uniform particle dispersion, optimal grain refinement, and favorable precipitation of intermetallic phases, including Al<sub>2</sub>Cu, Al<sub>2</sub>CuMg, and Al-Cu-Zn. An excess reinforcement (6–8 wt.%) leads to particle agglomeration, grain coarsening, and phase heterogeneity. The corrosion resistance is assessed using Tafel polarization tests in a&#xa0;3.5 wt.% NaCl solution. The 4 wt.% brass composites demonstrate the best corrosion resistance, with the most noble Ecorr (+72 mV), the minimal pitting, and the lowest corrosion rate (1.1⋅10<sup>−3</sup> mpy), attributed to its uniform microstructure and stable intermetallic phases. Higher brass contents increase the galvanic activity, cause negative Ecorr values, and severe localized corrosion due to clustering and microgalvanic coupling.</p>

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A novel approach to enhancing corrosion resistance in aluminum matrix composites via brass reinforcement through friction stir processing

  • 期刊论文

  • 发表日期：

    2026年7月8日

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  • Chinthakunta Siva Reddy,
  • P. Veera Sanjeeva Kumar

摘要

The microstructural evolution and corrosion behavior of AA2024 aluminum matrix composites reinforced with varying weight percentages (2, 4, 6, and 8 wt.%) of brass particles, processed by Friction Stir Processing (FSP) are investigated. The microstructural characterization by optical microscopy, scanning electron microscopy (SEM), and XRD reveals that 4 wt.% brass provides the most uniform particle dispersion, optimal grain refinement, and favorable precipitation of intermetallic phases, including Al2Cu, Al2CuMg, and Al-Cu-Zn. An excess reinforcement (6–8 wt.%) leads to particle agglomeration, grain coarsening, and phase heterogeneity. The corrosion resistance is assessed using Tafel polarization tests in a 3.5 wt.% NaCl solution. The 4 wt.% brass composites demonstrate the best corrosion resistance, with the most noble Ecorr (+72 mV), the minimal pitting, and the lowest corrosion rate (1.1⋅10−3 mpy), attributed to its uniform microstructure and stable intermetallic phases. Higher brass contents increase the galvanic activity, cause negative Ecorr values, and severe localized corrosion due to clustering and microgalvanic coupling.