Part I. Corrosion studies of continuous alumina fiber reinforced aluminum-matrix composites. Part II. Galvanic corrosion between continuous alumina fiber reinforced aluminum-matrix composites and 4340 steel

Part I. The corrosion performance of continuous alumina fiber reinforced aluminum-matrix composites (CF-AMCs) was investigated in both the laboratory and field environments by comparing them with their respective monolithic matrix alloys, i.e., pure Al, A1-2wt%Cu T6, and Al 6061 T6. The corrosion initiation sites were identified by monitoring the changes in the surface morphology. Corrosion current densities and pH profiles at localized corrosion sites were measured using the scanning-vibrating electrode technique and the scanning ion-selective electrode technique, respectively. The corrosion damage of the materials immersed in various electrolytes, as well as those exposed in a humidity chamber and outdoor environments, was evaluated. Potentiodynamic polarization behavior was also studied.;The corrosion initiation for the composites in 3.15 wt% NaCl occurred primarily around the Fe-rich intermetallic particles, which preferentially existed around the fiber/matrix interface on the composites. The corrosion initiation sites were also caused by physical damage (e.g., localized deformation) to the composite surface.;At localized corrosion sites, the buildup of acidity was enhanced by the formation of micro-crevices resulting from fibers left in relief as the matrix corroded. The composites that were tested in exposure experiments exhibited higher corrosion rates than their monolithic alloys. The composites and their monolithic alloys were subjected to pitting corrosion when anodically polarized in the 3.15 wt% NaCl, while they passivated when anodically polarized in 0.5 M Na2SO4.;The experimental results indicated that the composites exhibited inferior corrosion resistance compared to their monolithic matrix alloys.;Part II. Galvanic corrosion studies were conducted on CF-AMCs coupled to 4340 steel since CF-AMCs have low density and excellent mechanical properties and are being considered as potential jacketing materials for reinforcing steel gun barrels. Coupled and uncoupled coupons were immersed in various electrolytes, exposed to a humidity chamber, and exposed at outdoor test sites. Results showed that the corrosion rates of the CF-AMCs increased, while those of the 4340 steel decreased after being coupled together, in most cases. Crevice corrosion was also observed in these exposure experiments.;Zero resistance ammeter (ZRA) experiments were conducted to record the galvanic-corrosion rates and potentials of the couples. The CF-AMCs were found to serve as anodes, while the steel was cathodic, in most test conditions. Galvanic performance predicted by polarization experiments was in close agreement with the ZRA results.;Key words. Aluminum, metal-matrix composites, alumina fiber, pitting corrosion, galvanic corrosion.