Microstructure and Corrosion Behavior of Friction Stir Welded Al Alloy Coated by In Situ Shot-Peening-Assisted Cold Spray

doi:10.1007/s40195-019-00966-4

Abstract

Abstract:

To improve the corrosion resistance of friction stir welded (FSW) joints, in situ shot-peening-assisted cold spray coating was applied to the surface of FSW joints. The microstructure and corrosion behavior of the coatings were investigated. The results showed that a dense coating was obtained by cold spraying technology. Moreover, the use of in situ shot-peening-assisted technology significantly reduced the porosity of the coating, which has a positive impact on the microstructure and the mechanical performance. Exfoliation corrosion tests showed that the coating affected positively on the corrosion resistance. On the coated surface, the craters caused by shot-peening particles were corroded in the form of exfoliation corrosion, while the exposed particles were corroded in the form of intercrystalline corrosion. This work provides a new approach to the corrosion protection of FSW joints.

Key words: Aluminum alloy coating, Cold spray, Friction stir welding, In situ shot-peening, Intergranular corrosion

Hua Zhang, Chang-Yu Zhao, Qi-Long Guo, Rui-Sheng Yang, Li-Yuan Liu, San-Bao Lin. Microstructure and Corrosion Behavior of Friction Stir Welded Al Alloy Coated by In Situ Shot-Peening-Assisted Cold Spray[J]. Acta Metallurgica Sinica (English Letters), 2020, 33(1): 172-182.

Figures/Tables 12

Fig. 1 a Morphology of AA2219 powder, b, c TEM images, d EDX spectrum, e EDS map of a particle cross section

Fig. 2 Cross sections of the FSW joint after cold spraying: a whole view, b BM, c HAZ, d TMAZ/WNZ

Fig. 3 Cross sections of a conventional CS coating, b in situ shot-peening-assisted CS coating

Fig. 4 Optical images of in situ shot-peening-assisted CS coating: a thickness of the CS coating, b interface, c inner coating, d surface coating

Fig. 5 SEM images of the coating: a top view surface, b inner coating

Fig. 6 a, b TEM images, c EDS map of in situ shot-peening-assisted CS coating

Fig. 7 Model of plastic deformation during the spraying

Fig. 8 Micro-hardness of FSW joint

Fig. 9 Cross sections of the interface: a CS/BM, b CS/HAZ, c CS/TMAZ, d CS/WNZ

Fig. 10 Fracture appearance of a in situ shot-peening-assisted CS coating, b inter-particle junction, c layered microstructure

Fig. 11 Three-dimensional maps of corrosion morphology in different areas: a BM, b HAZ/TMAZ, c WNZ, d coating

Fig. 12 Corrosion morphologies of in situ shot-peening-assisted CS coating in EXCO solution for different immersion time

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