Understanding the corrosion behaviour of 7xxx series aluminium alloys under galvanic corrosion conditions

Abstract

For decades, developments towards a chromate-free protective system have been a crucial quest in the aerospace industry. In this search, innovation starts with a comprehensive understanding of the aircraft complex multi-material structures and the corrosion mechanisms involved. These complex structures, with aluminium the most dominant substrate, are used to optimize the strength to weight ratio, fatigue properties and operational performance in aircraft design. On the other hand, the use of multi-materials can cause an accelerated corrosion attack, called galvanic corrosion. This type of corrosion can be advantageously applied to galvanically protect a material but can also occur undesirably with serious accelerated degradation as result.

This thesis aims to increase our understanding of corrosion on AA7XXXClad alloys as stand-alone material, as well as in configurations relevant for galvanic corrosion with other metals. The understanding of these phenomena should support the definitions of new hypotheses on how these alloys can be better protected using chromate-free coating technologies. Two commonly used aluminium alloys in the aerospace industry have been investigated in this study because a selective galvanic stimulated dissolution of the cladding layer material was found after an accelerated corrosion test. This selective dissolution makes it difficult for the corrosion inhibitors to reach the exact site of corrosion propagation in the cladding layer, reducing the inhibition efficiency and allowing corrosion to propagate.

Since Zinc is the main alloying element in the substrate and cladding material, the role of Zn with respect to corrosion initiation and propagation was investigated first. Subsequently, the behaviour of clad alloys under galvanic corrosion conditions, and finally how inhibition under these conditions can be reliably assessed. This was performed by a combination of multiple electrochemical techniques and microscopic analysis. The results demonstrate that Zn plays a significant role in the dissolution of the cladding layer and may be held responsible for the selective dissolution observed. In addition, an experimental procedure was developed to measure the coupled galvanic parameters and to simulate the galvanic corrosion degradation in industrial desired timeframes. Although simulation of the phenomenon has shown to be promising with in-situ experiments, it was not fully observed. Furthermore, to test the performance of corrosion inhibitors, a procedure is developed with and without the use of coatings. In general, it can be concluded that limiting the cathodic reactions is of paramount importance to reduce the galvanic corrosion current.