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<p>This study investigates the corrosion behavior of FSWed SS304/AA2024-T3 joints in chloride-rich environments, focusing on welding-induced microstructural changes affecting localized and galvanic corrosion. FSW was performed using optimized parameters: 560&#xa0;rpm tool rotation, 25&#xa0;mm/min welding speed, 1.75° tilt angle, and 1.5&#xa0;mm tool pin offset toward the Al side. Microstructural analysis revealed an ultra-refined stir zone (SZ) with a 4.2&#xa0;μm average grain size due to plastic deformation (PD) and dynamic recrystallization (DRX). 360&#xa0;h corrosion immersion testing in 3.5% NaCl solution showed the FSWed joint had a corrosion rate (CR) of 0.0203&#xa0;mm/year, significantly lower than AA2024-T3 (CR = 0.1044&#xa0;mm/year) and similar to SS304 (CR = 0.0173&#xa0;mm/year). Corrosion morphology indicated pitting, intergranular corrosion (IGC), and blistering at the Al/SS interface due to galvanic effects and intermetallic compounds (IMCs) like FeAl₃. While FSW improves corrosion resistance via grain refinement, galvanic interactions and interface heterogeneity highlight the need for interface optimization and surface treatments for better marine durability.</p>

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In Vitro Corrosion Response of FSW Processed Al-Cu-Mg/Fe-Cr-Ni Dissimilar Alloys for Marine Applications

  • 期刊论文

  • 发表日期：

    2026年1月30日

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  • Fayaz Ahmad Mir,
  • Noor Zaman Khan,
  • Turali Narayana,
  • Nadeem Fayaz Lone,
  • Arshad Noor Siddiquee,
  • Firdoos Afzal Bhat,
  • Haseeb A khan,
  • Salman H Alrokayan

摘要

This study investigates the corrosion behavior of FSWed SS304/AA2024-T3 joints in chloride-rich environments, focusing on welding-induced microstructural changes affecting localized and galvanic corrosion. FSW was performed using optimized parameters: 560 rpm tool rotation, 25 mm/min welding speed, 1.75° tilt angle, and 1.5 mm tool pin offset toward the Al side. Microstructural analysis revealed an ultra-refined stir zone (SZ) with a 4.2 μm average grain size due to plastic deformation (PD) and dynamic recrystallization (DRX). 360 h corrosion immersion testing in 3.5% NaCl solution showed the FSWed joint had a corrosion rate (CR) of 0.0203 mm/year, significantly lower than AA2024-T3 (CR = 0.1044 mm/year) and similar to SS304 (CR = 0.0173 mm/year). Corrosion morphology indicated pitting, intergranular corrosion (IGC), and blistering at the Al/SS interface due to galvanic effects and intermetallic compounds (IMCs) like FeAl₃. While FSW improves corrosion resistance via grain refinement, galvanic interactions and interface heterogeneity highlight the need for interface optimization and surface treatments for better marine durability.