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<p>This paper examines the corrosion susceptibility of additively manufactured AA7050 constructed utilizing the additive friction stir deposition (AFSD) process. Because large-scale, multilayer builds impart additional heat into prior deposition layers of the AFSD build, this paper focuses on characterizing the corrosion resistance between different layers of the AFSD build, while also making comparisons to the wrought AA7050-T7451 control samples. Potentiodynamic polarization tests were used for quantitative analyses, while immersion tests and optical microscopy were used for qualitative analyses. Scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), and transmission electron microscopy (TEM) were used for microstructural analyses. The results showed both an overall increase in the corrosion current density of AFSD AA7050 paired with more active corrosion potential and repassivation potential values when compared to the control AA7050 (T7451). In AFSD, grain sizes were reduced by an order of magnitude compared to the substrate, while the intermetallic particle size increased by anywhere from 400 (top) to 900% (bottom), depending on the depth within the multilayer build. These variations in microstructure resulted in a twofold increase in the corrosion rate in AFSD AA7050 compared to the wrought controls. Additionally, immersion testing demonstrated differences in corrosion mechanisms across various depths due to the artificial aging caused by both the residual heat and continued heat input from each subsequent layer. Furthermore, preferential corrosion at the layer interfaces was also observed in immersion testing.</p>

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Examination of the Corrosion Susceptibility of a Multilayer AA7050 Additive Friction Stir Deposition Build

  • 期刊论文

  • 发表日期：

    2025年5月16日

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  • Justin B. Geisler,
  • Rekha M. Y.,
  • Jacob E. Strain,
  • Luke N. Brewer,
  • J. Brian Jordon,
  • Paul G. Allison,
  • Gregory W. Kubacki

摘要

This paper examines the corrosion susceptibility of additively manufactured AA7050 constructed utilizing the additive friction stir deposition (AFSD) process. Because large-scale, multilayer builds impart additional heat into prior deposition layers of the AFSD build, this paper focuses on characterizing the corrosion resistance between different layers of the AFSD build, while also making comparisons to the wrought AA7050-T7451 control samples. Potentiodynamic polarization tests were used for quantitative analyses, while immersion tests and optical microscopy were used for qualitative analyses. Scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), and transmission electron microscopy (TEM) were used for microstructural analyses. The results showed both an overall increase in the corrosion current density of AFSD AA7050 paired with more active corrosion potential and repassivation potential values when compared to the control AA7050 (T7451). In AFSD, grain sizes were reduced by an order of magnitude compared to the substrate, while the intermetallic particle size increased by anywhere from 400 (top) to 900% (bottom), depending on the depth within the multilayer build. These variations in microstructure resulted in a twofold increase in the corrosion rate in AFSD AA7050 compared to the wrought controls. Additionally, immersion testing demonstrated differences in corrosion mechanisms across various depths due to the artificial aging caused by both the residual heat and continued heat input from each subsequent layer. Furthermore, preferential corrosion at the layer interfaces was also observed in immersion testing.