Microstructure and Corrosion Performance of Mg/AlCoCrFeNi2.1 Composites Produced via Friction Stir Processing

NI Yu; XU Hui; XIONG Feng; LIANG Yonglin; ZHANG Pengxian; ZHANG Changqing; JIN Yuhua; QIAO Sheng; ZHU Tiecheng

doi:10.16490/j.cnki.issn.1001-3660.2026.14.004

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Surface Technology ›› 2026, Vol. 55 ›› Issue (14) : 44-54. DOI: 10.16490/j.cnki.issn.1001-3660.2026.14.004

Corrosion and Protection

Microstructure and Corrosion Performance of Mg/AlCoCrFeNi_2.1 Composites Produced via Friction Stir Processing

NI Yu^1a,1b,2,*, XU Hui^1a,1b, XIONG Feng^1a,1b, LIANG Yonglin^1a,1b, ZHANG Pengxian^1a,1b, ZHANG Changqing^1a,1b, JIN Yuhua^1a,1b, QIAO Sheng³, ZHU Tiecheng³

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Abstract

With the continuous global demand for lightweight materials, the application of magnesium alloys continues to expand. However, their widespread adoption is significantly constrained by inherent drawbacks such as low hardness and poor corrosion resistance. To address these challenges, the strategy of developing composites has been proposed by researchers. The core of this approach involves introducing reinforcement materials into the magnesium alloy matrix, which can modify its strengthening mechanisms and thereby endow MMCs with a series of superior properties. Among various candidate reinforcement materials, HEAs represent a promising choice. HEAs possess excellent comprehensive properties. Furthermore, the high-entropy effect can suppress the formation of intermetallic compounds at interfaces, making them ideal reinforcement particles. Nevertheless, traditional processing methods for MMCs are prone to issues such as particle agglomeration, oxidation loss, and interfacial defects. Therefore, this study employs FSP to fabricate AZ31B/AlCoCrFeNi_2.1 composites to enhance the surface properties of magnesium alloys and systematically investigate the influence of the HEA content on the microstructure and corrosion performance of the composites.
The MMCs are fabricated using an FSW-3LM-015 friction stir welding system. The process parameters for both the sealing and the FSP passes are set as follows: a rotation speed of 1 500 r/min, a traverse speed of 40 mm/min, and a plunge depth of 3.5 mm. After processing, metallographic specimens and corrosion samples are extracted from the center of the processed zone using wire electrical discharge machining. The surface morphology, microstructure, phase distribution, and elemental diffusion of the composites are characterized by OM and SEM. The corrosion performance of the composites is evaluated with an electrochemical workstation. The corrosion morphology of the composites is observed by SEM, and the composition of the corrosion product formed on the composite surface after corrosion is analyzed by X-ray photoelectron spectroscopy (XPS).
Microstructural observations reveal that compared with the BM, the grain size of the composites is significantly reduced. Relative to the BM grain size of 25.2 μm, the grain size of the MMCs gradually decreases from 5.69 μm to 4.81 μm as the HEA filler content increases from 10% to 20%. Concurrently, the number of twins in the composites decreases markedly. The HEA particles are uniformly distributed within the BM, and their interfaces exhibit good bonding without defects. Only limited elemental diffusion occurs between the HEAs and the BM. The MMCs demonstrate improved corrosion resistance, which gradually increases with the increasing HEA filler content. When the HEA filler content reaches 20%, the corrosion potential shifts positively, and the corrosion current density decreases from 8.710 × 10^-5 A/cm² for the BM to 1.479 × 10^-5 A/cm² for the MMC. Analysis of the corrosion morphology indicates that corrosion cracks and pits on the MMC surface are significantly reduced. The presence of HEA particles inhibits the rapid propagation of surface corrosion reactions, resulting in a more uniform corrosion area. XPS results indicate that FSP promotes the formation of MgO, and a dense Cr₂O₃ oxide forms on the MMC.
In summary, the surface properties of the composites are substantially enhanced through the combined effects of friction stir processing (grain refinement) and high-entropy alloy particles (pinning effect + formation of a dense passive film).

Key words

friction stir processing / composites / high-entropy alloy / microstructure / corrosion performance

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NI Yu, XU Hui, XIONG Feng, LIANG Yonglin, ZHANG Pengxian, ZHANG Changqing, JIN Yuhua, QIAO Sheng, ZHU Tiecheng. Microstructure and Corrosion Performance of Mg/AlCoCrFeNi_2.1 Composites Produced via Friction Stir Processing[J]. Surface Technology. 2026, 55(14): 44-54

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Funding

The Postdoctoral Program in Gansu Province (25JRRA141); The National Natural Science Foundation of China (52465043); The Young Talent Project in Gansu Province (2026QNTD047); The National Natural Science Foundation of China (52261013); The Major Science and Technology Projects in Gansu Province (24ZD13GA018); The 2024 University Industry Support Project of Gansu Province (2024CYZC-20)