| LOU Yuntian,YU Zhihao,CHANG Weiwei,QIAN Hongchang,Guo，Dawei,ZHANG Dawei.Corrosion Behaviour of Different Deposition Layers in AA6061 Aluminum Alloy Produced via Additive Friction Stir Deposition[J],54(8):84-95 |
| Corrosion Behaviour of Different Deposition Layers in AA6061 Aluminum Alloy Produced via Additive Friction Stir Deposition |
| Received:March 26, 2025 Revised:April 12, 2025 |
| View Full Text View/Add Comment Download reader |
| DOI：10.16490/j.cnki.issn.1001-3660.2025.08.007 |
| KeyWord:additive friction stir deposition aluminum alloy intermetallic compound corrosion behavior |
| Author | Institution |
| LOU Yuntian |
Institute for Advanced Materials and Technology, University of Science and Technology Beijing, Beijing , China;Shunde Innovation School, University of Science and Technology Beijing, Guangdong Foshan , China |
| YU Zhihao |
Institute for Advanced Materials and Technology, University of Science and Technology Beijing, Beijing , China;Shunde Innovation School, University of Science and Technology Beijing, Guangdong Foshan , China |
| CHANG Weiwei |
Institute for Advanced Materials and Technology, University of Science and Technology Beijing, Beijing , China;Shunde Innovation School, University of Science and Technology Beijing, Guangdong Foshan , China |
| QIAN Hongchang |
Institute for Advanced Materials and Technology, University of Science and Technology Beijing, Beijing , China;Shunde Innovation School, University of Science and Technology Beijing, Guangdong Foshan , China |
| Guo，Dawei |
IDQ Science and Technology Development Hengqin, Guangdong Co., Ltd., Guangdong Zhuhai , China |
| ZHANG Dawei |
Institute for Advanced Materials and Technology, University of Science and Technology Beijing, Beijing , China;Shunde Innovation School, University of Science and Technology Beijing, Guangdong Foshan , China |
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| Abstract: |
| Solid-state additive manufacturing is an advanced fabrication technology that does not rely on material melting. It primarily includes techniques such as ultrasonic additive manufacturing, cold spray additive manufacturing, and additive friction stir deposition (AFSD). Among these, AFSD combines the principles of friction stirring with continuous material feeding to create a unique solid-state and low-temperature additive process. Compared with conventional fusion-based additive manufacturing, the low thermal input and extensive plastic deformation in AFSD promote the formation of fine equiaxed microstructures and defect-free interiors, thereby significantly enhancing the mechanical properties of the fabricated parts. In addition, AFSD can be carried out in open environments and is easily scalable, making it particularly suitable for the fabrication and repair of large-scale components. At present, AFSD remains the only metal additive manufacturing technique capable of achieving mechanical properties comparable to forging. In recent years, the AFSD process has become increasingly mature and has been widely applied in the solid-state additive manufacturing of aluminum alloys, especially gaining significant attention in studies on 6xxx series alloys. This study investigates the effects of additive friction stir deposition (AFSD) and subsequent T6 heat treatment on the distribution of intermetallic compounds and the corrosion resistance across different layers of multilayer-deposited AA6061 aluminum alloy. AA6061 aluminum alloy coupons are fabricated using the AFSD process and then subject to T6 heat treatment. Samples are taken from the upper, middle, and lower layers. The type and distribution of intermetallic precipitates are analyzed by scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), and ImageJ image processing. Corrosion behavior is characterized by electrochemical impedance spectroscopy (EIS), while corrosion products and pit morphologies are examined by X-ray diffraction (XRD) and confocal laser scanning microscopy (CLSM). The as-deposited and heat-treated samples mainly contain Mg2Si and AlFeSi intermetallic compounds. Compared with the base metal, the intermetallic phases in the AFSD samples are significantly refined, more uniformly distributed, and markedly increased in number. After heat treatment, the amount of intermetallic compounds is reduced but remains higher than that in the base metal. Due to the greater thermal cycling experienced by the lower layers during deposition, a larger number of precipitates are observed in these regions. Electrochemical tests reveal a layer-dependent corrosion resistance, following the trend upper > middle > lower. Heat-treated samples exhibit improved corrosion resistance owing to the partial dissolution of intermetallic back into the solid solution. Corrosion morphology also confirms that the lower layers show the most severe pitting after immersion. The Mg2Si and AlFeSi precipitates in AFSD samples exhibit non-uniform distribution along the build direction, with the lower layers showing the poorest corrosion resistance. T6 heat treatment reduces the amount of precipitates and enhances corrosion performance. In practical applications, corrosion resistance variation should be carefully evaluated based on service conditions, with preference given to the upper heat-treated regions. Additional surface coatings may further enhance corrosion protection. This work goes beyond previous studies that focus on single performance metrics, offering a comprehensive investigation into the evolution of intermetallic, electrochemical behavior, and corrosion morphology before and after heat treatment. The findings provide valuable insights for understanding corrosion mechanisms and optimizing corrosion resistance in AFSD-processed aluminum alloys. |
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