Cerium-based compounds have been studied for decades as non-toxic candidates for the protection of aerospace aluminium alloys (AAs) like AA2024-T3. However, the complex heterogeneous microstructure of these alloys has hindered a thorough understanding of the subsequent stages of corrosion protection provided by this class of inhibitors. Thus, this work is devoted to unravelling the interaction mechanisms of different intermetallic particles (IMPs) in AA2024-T3 with cerium nitrate at the nanoscopic scale. This has been fulfilled through detailed top-view and cross-sectional analytical TEM investigations along with electrochemical evaluations. In line with our recent findings, we here report dealloying of IMPs as the main factor governing the rate of local cerium precipitation in contrast to micro-galvanic corrosion between IMPs and the surrounding matrix. Furthermore, we discuss a connection between the electrochemical response of the AA2024-T3 system and the morphological and compositional evolutions of individual IMPs including Al2CuMg, Al2Cu, Al7Cu2Fe(Mn) and Al76Cu6Fe7Mn5Si6 at different stages of a 96-h exposure.

This work focuses on the cross-sectional characterization of the protective conversion layer formed on AA2024-T3 by lithium-leaching from a polyurethane coating in a corrosive environment. The layer shows a multi-layered arrangement comprising nanoscopic local phases. Transmission electron microscopy (TEM) and complementary high-resolution secondary ion mass spectroscopy (SIMS) were employed to observe the cross-sections of the entire layer formed at different locations of a 1-mm-wide scribe, in terms of morphology, structure and chemical composition. The conversion layer was comprised of two ubiquitous sublayers; a thin dense layer (i.e. 150 nm) adjacent the alloy substrate and a porous layer. The former represents an amorphous lithium-containing pseudoboehmite phase, Li-pseudoboehmite, whereas the latter is composed of amorphous and crystalline products; an outer columnar layer merely seen on the peripheral region is also crystalline. Through a sandwich structure and the d₍₀₀₃₎ basal spacing, the crystalline phases were identified as Li-Al layered double hydroxide. Although lithium was found uniformly spread within different regions, the local phases with no/low concentration of lithium were revealed with energy filtered TEM and confirmed with SIMS analysis.

Dealloying is involved in materials science responsible for fabrication of nanoscale structures beneficially but for corrosion degradations detrimentally. Detailed understanding related to the latter is critical for designing corrosion-resistance alloys and dedicated inhibition systems. Thus, direct nanoscopic observations of nano-structural and compositional evolutions during the process are essential. Here using liquid phase-transmission electron microscopy (LP-TEM), for the first time, we show dynamic evolution of intricate site-specific local corrosion linked to intermetallic particles (IMPs) in aerospace aluminium alloys. To thoroughly probe degradation events, oxidation direction is controlled by purposefully masking thin specimens, allowing for observing top-view surface initiation to cross-sectional depth propagation of local degradations. Real-time capturing validated and supported by post-mortem examinations shows a dealloying-driven process that initiates at IMPs and penetrates into the depth of the alloy, establishing macroscopic corrosion pits. Besides, controversial mechanisms of noble-metal redistribution are finally elucidated.

Nanoscopic characterization of heterogeneous intermetallic particles (IMPs) which microstructurally and compositionally evolve during local corrosion is crucial in unravelling the mechanisms and sequence of initial and local corrosion events. Herein, we study site-specific initiation events focused on microscopic constituent intermetallic compounds and nanoscopic dispersoids in AA2024-T3 at the nanoscale using a combined quasi in-situ and ex-situ analytical TEM approach. Our findings show a dealloying-driven local corrosion initiation at the studied IMPs that have been considered as cathodic phases traditionally. Besides, local degradation which is a result of galvanic interactions between dealloyed regions of IMPs and their adjacent alloy matrix is largely governed by the intrinsic electrochemical instability of intermetallic compounds.