<p>This study investigated the optimization of semisolid casting for aluminum sacrificial anodes to enhance corrosion performance and refine microstructure. Response surface methodology and computational modeling approach were employed to optimize cooling slope casting parameters (temperature, angle, and length) to achieve improved sphericity, reduced grain size, and an increased corrosion rate. The effect of magnesium additions (1–3 wt.%) on the alloy's properties was also examined. Electrochemical performance was evaluated through potentiodynamic polarization, electrochemical impedance spectroscopy, chronoamperometry, optical microscopy, and scanning electron microscopy for microstructural analysis. The incorporation of 2 wt.% magnesium produced the most favorable results, increasing the corrosion rate to 0.324&#xa0;mm/year and achieving an output current of 0.43 A. Based on microstructural and electrochemical analyses, the alloy containing 2 wt.% Mg exhibited the most promising characteristics for sacrificial anode applications, identifying it as the optimal composition.</p>

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Magnesium's Impact on Microstructure and Electrochemical Behavior of Al–Zn–In Sacrificial Anodes via Cooling Slope Casting: A Surface Response Analysis Model

  • Mojtaba Soltanpour,
  • Behrooz Shayegh Boroujeny,
  • Amir Abbas Nourbakhsh,
  • Farzad Abbasian,
  • Pegah Izadi,
  • Ebrahim Mohseni Homagerani

摘要

This study investigated the optimization of semisolid casting for aluminum sacrificial anodes to enhance corrosion performance and refine microstructure. Response surface methodology and computational modeling approach were employed to optimize cooling slope casting parameters (temperature, angle, and length) to achieve improved sphericity, reduced grain size, and an increased corrosion rate. The effect of magnesium additions (1–3 wt.%) on the alloy's properties was also examined. Electrochemical performance was evaluated through potentiodynamic polarization, electrochemical impedance spectroscopy, chronoamperometry, optical microscopy, and scanning electron microscopy for microstructural analysis. The incorporation of 2 wt.% magnesium produced the most favorable results, increasing the corrosion rate to 0.324 mm/year and achieving an output current of 0.43 A. Based on microstructural and electrochemical analyses, the alloy containing 2 wt.% Mg exhibited the most promising characteristics for sacrificial anode applications, identifying it as the optimal composition.