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Impact of cooling methods on the corrosion behavior of AA6063 aluminum alloy in a chloride solution

  • El-Sayed M. Sherif , Ibrahim A. Alnaser and Adel Taha Abbas EMAIL logo
Published/Copyright: August 27, 2024
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Science and Engineering of Composite Materials
From the journal Science and Engineering of Composite Materials Volume 31 Issue 1

Abstract

In this work, the AA6063 Al alloy was processed by cooling at four different conditions. The impact of the type of cooling method on the corrosion behavior of the produced alloys after 1 and 24 h in 3.5% NaCl solutions was carried out. Various electrochemical measurements, such as cyclic potentiodynamic polarization (CPP), chronoamperometric, and electrochemical impedance spectroscopy (EIS) measurements, were employed. The CPP data revealed that the intensity of corrosion of the alloys is highly influenced by the cooling method. The change in the chronoamperometric current at −650 mV (Ag/AgCl) over time indicates the possibility of pitting corrosion, particularly after 24 h, where the recorded currents showed a continuous increase over time. The scanning electron microscopy images taken for the surfaces of the alloys after corrosion confirmed that the lowest deterioration occurring on the surface was for the AA6063 alloy that was quenched in water. The EIS plots also demonstrated that AA6063 alloy exhibits different corrosion resistances when different cooling methods are applied. All measurements indicated that the corrosion resistance increases in the following order: the quenched alloy in water > the air-cooled alloy > the furnace-cooled alloy > the as-received alloy. The exposure for 24 h decreases the corrosion damage of all alloys via the formation and thickening of a top layer of corrosion products on its surface over time.

Keywords: AA6063 aluminum alloy; heat treatment; corrosion; potentiodynamic polarization; impedance spectroscopy; surface investigation

1 Introduction

Aluminum and some of its alloys widely suffer from corrosion, particularly pitting, when exposed to corrosive environments containing chloride ions [1,2,3,4,5,6,7]. AA6063 is an aluminum alloy known for its excellent extrudability, moderate strength, good weldability, and resistance to various types of corrosion. Due to these features, the AA6063 alloy finds numerous applications, such as in furniture, doors, architectural extrusions, pipes, window frames, road transport, rail transport, truck, trailer floors, hospital, and medical equipment [6,7,8,9].

The addition of alloying elements has been one of the most commonly used techniques to achieve improved corrosion resistance [10,11,12]. Heat treatment has also been employed to enhance the resistance of Al alloys to corrosion. In earlier work, the change in the extrusion temperature on the behavior of corrosion for the recycled Al alloy 6061 chips in sodium chloride solution has been reported [13]. It was found that increasing the extrusion temperature from 350 to 500°C led to an increase in the resistance to corrosion for the alloy due to the reduction in the output current and the measured rate of corrosion. Kharitonov et al. [4] have reported the corrosion mechanism of AA6063 alloy and found that this alloy is prone to localized corrosion, particularly the pitting attack. The corrosion of AA6063-T5 Al alloy in NaCl solution that contains molybdate using various techniques has been investigated [5]. The inhibition of AA6063 alloy in different seawaters using Solanum erianthum extract was studied by Bodude et al. [14]. The inhibitor exhibited an inhibition efficiency of about 96% in the deep, shallow, and lagoon different seawater environments, obtained using the potentiodynamic polarization technique. Mahmood et al. [15] have also studied the corrosion of AA6063 alloy for the ferric chloride corrosion product. They have found that multiple wet periods with small droplet volumes caused a higher corrosion rate compared to exposure to a single droplet. Another investigation on the behavior of corrosion of laser cladding coatings of Al3Ti-based composite that was applied on alloy AA6063 has also been reported by He et al. [16]. The application of Al3Ti coating on the surface remarkably increased the resistance to corrosion compared to the substrate of the alloy. The effect of different cooling methods on the corrosion behavior at the welded area of aluminum alloy was reported by Nik et al. [17], and they found that cooling the samples in air shows a different corrosion rate than that for the samples quenched in water. The effect of quenching conditions on the corrosion behavior of 6063 Al alloy has been reported by He et al. [18], who found that quenching the alloy in water improves its corrosion resistance. The authors [18] also found that the air-cooled 6063 Al alloy samples have much lower corrosion resistance compared to those quenched in water.

The present work investigates the influence of different cooling conditions on the corrosion of AA6063 in a 3.5% NaCl solution. The first alloy was used as-received, the second alloy was allowed to cool inside the furnace, the third alloy was cooled in the air, and the fourth alloy was cooled by quenching in the water. The corrosion experiments were conducted in triplicate using a new portion of the solution and a fresh alloy surface at room temperature after 1 and 24 h in the test electrolyte.

2 Materials and methods

2.1 Alloy processing

The used alloy was an AA6063 aluminum alloy with the following composition: 0.40% Si, 0.32% Fe, 0.60% Mg, 0.08% Cu, 0.08% Zn, 0.07% Cr, 0.07% Ti, 0.09% Mn, and the rest was Al. The plates of AA6063 aluminum alloy with 30 mm thickness were received under hot-rolled and normalized conditions. The Emco conventional lathe type (EMCOMAT20D) was used to round the samples to cylindrical bars with 10 mm diameter and 50 mm length. This turning machine has the following specifications: electronic speed control, 40–3,000 rpm; longitudinal feed, 0.045–0.787 mm/rev; drive motor, 5.3 kW; and step-less speeds. The carbide tool inserts with wiper geometry type (DCMX11 T304-WF 4315) were used to process all samples. Furnace-type Carbolite with the following specifications, 220 V, 3 phase, 50–60 Hz, and 6222 W, and a maximum temperature of 1,300°C, was used to carry the heat treatment. This furnace has inner dimensions of 20 cm length × 20 cm width × 20 cm height. The samples were heat treated using the following procedures; a sample of this alloy (sample-1) was used as received and the three other samples of the alloy were subjected to different cooling treatments after being annealed at 500°C for 8 h. One of those three samples (sample-2) was cooled inside the furnace. Another sample was left to cool in air (sample-3). The last annealed alloy was directly cooled by quenching in water (sample-4). The dimensions of each of these four samples were 1 cm length × 1 cm width × 0.4 cm height.

2.2 Electrochemical cell and electrochemical experiments

An electrochemical cell of a three-electrode configuration containing a 200 mL solution of NaCl was employed. The solution of 3.5% NaCl was prepared from a 99% purity NaCl salt. Rods of the Al samples, a platinum (Pt) sheet, and an Ag/AgCl were employed as working, counter, and reference electrodes, respectively. The samples were prepared and polished for performing the tests as previously reported [17,18,19]. In brief, the samples were welded with a copper wire from one surface and then mounted in an inert epoxy coating, leaving only one surface without epoxy. The surface, which was not covered with epoxy, was polished with emery papers with different grits (from 200 to 800). The dimensions of each polished surface were 1 cm in length × 1 cm in width with a total surface area of 1 cm2. All electrochemical experiments were collected using an Autolab model Ecochemie PGSTAT-302N. The polarization curves were obtained by scanning the potential in the forward direction from −1,500 to −500 mV. The potential was directly rescanned again from −500 mV in the backward direction till the reversed current intersects with the current obtained from the forward direction. The scan rate for all CPP experiments was 1.67 mV/s. The EIS plots were measured at the open-circuit potential at frequency values ranging from 100,000 Hz to 0.10 Hz, as reported in our recent works [19,20]. The change in the current over time plots was collected at −650 mV for the different samples for 2,200 s.

3 Results and discussion

3.1 Cyclic potentiodynamic polarization (CPP) results

The CPP experiments were employed to understand the effect of changing the cooling conditions for the AA6063 alloy on its corrosion. The curves of CPP obtained for samples after immersion for 1 h are displayed in Figure 1. The CPP measurements were also performed after 24 h, and the curves are shown in Figure 2. The corrosion data, namely, the cathodic Tafel slope (β c), the anodic Tafel slope (β a), the corrosion potential (E Corr), the corrosion current (j Corr), the protection potential (E Prot), the pitting potential (E Pit), the polarization resistance (R P), and the corrosion rate (R Corr) were obtained, and are listed in Table 1. Most of these values were obtained, as previously reported [19,20,21,22,23,24]. As shown in Figure 1a, the values of E Prot were obtained from the intersection of the forward and the backward anodic currents. Also, the values of E Pit refer to the potential at which the pitting corrosion occurs. The values of R P and R Corr were calculated using Equations (1) and (2), respectively [19,20,21,22,23,24]:

(1) R P = 1 j Corr β c · β a 2.3 ( β c + β a ) ,

(2) R Corr = j Corr k · E W d · A ,

where k is a constant (= 3,272 mm (amp/cm/year)), E W is the equivalent weight of Al (= 9 gram equivalent), d is the density of Al (= 2.70 g/cm3), and A is the area of the Al electrode (= 1 cm2).

Figure 1 CPP plots for (a) the as-received alloy (sample-1), (b) the furnace-cooled alloy (sample-2), (c) the air-cooled alloy (sample-3), and (d) the quenched alloy in water (sample-4) after their immersions for 1 h.
Figure 1

CPP plots for (a) the as-received alloy (sample-1), (b) the furnace-cooled alloy (sample-2), (c) the air-cooled alloy (sample-3), and (d) the quenched alloy in water (sample-4) after their immersions for 1 h.

Figure 2 CPP curves for (a) sample-1, (b) sample-2, (c) sample-3, and (d) sample-4 after 24 h immersion.
Figure 2

CPP curves for (a) sample-1, (b) sample-2, (c) sample-3, and (d) sample-4 after 24 h immersion.

Table 1

Parameters obtained from CPP curves

Sample β c/mV/dec E Corr/mV β a/mV/dec j Corr/µA/cm2 E Prot/mV E Pit/mV R P/kΩ/cm−2 R Corr/mmpy
Sample-1 (1 h) 120 ± 3 −1,243 ± 2 180 ± 3 1.8 ± 0.2 −800 ± 2 −737 ± 3 1.739 0.0196
Sample-2 (1 h) 112 ± 2 −1,165 ± 5 165 ± 2 0.75 ± 0.3 −793 ± 2 −692 ± 3 3.868 0.0082
Sample-3 (1 h) 108 ± 2 −1,135 ± 3 160 ± 3 0.38 ± 0.2 −790 ± 3 −700 ± 5 7.377 0.0041
Sample-4 (1 h) 100 ± 4 −992 ± 3 165 ± 4 0.27 ± 0.3 −813 ± 2 −690 ± 3 10.026 0.0029
Sample-1 (24 h) 115 ± 4 −1,000 ± 5 120 ± 3 0.5 ± 0.05 −785 ± 3 −650 ± 5 5.106 0.0055
Sample-2 (24 h) 110 ± 3 −1,110 ± 5 115 ± 4 0.10 ± 0.02 −770 ± 3 −662 ± 3 24.444 0.0011
Sample-3 (24 h) 108 ± 2 −935 ± 5 110 ± 3 0.08 ± 0.02 −765 ± 2 −645 ± 5 29.617 0.0009
Sample-4 (24 h) 110 ± 4 −950 ± 5 105 ± 4 0.06 ± 0.01 −770 ± 3 −635 ± 5 38.929 0.0007

The current on the cathodic side decreases with sweeping the potential for sample-1 (the as-received alloy (Figure 1a) till it reaches the lowest measured current value, which is also the value of j Corr. This is due to the reduction of the oxygen on the surface as follows [25,26,27,28,29]:

(3) H 2 O + 1 2 O 2 + 2 e − = 2 O H − .

The current increases again after reaching j Corr (on the anodic side) by the oxidation of the surface, causing its instant dissolution before the current becomes stable. The dissolution process for Al occurs [26,27,28]:

(4) Al = Al 3 + + 3 e − .

Surface passivation occurs via the adsorption of hydroxides that are produced from the cathodic reactions and transfer to oxide, leading to the surface formation of Al2O3. These reactions proceed according to the following equations [27]:

(5) Al + 3 O H − = Al ( O H ) 3 + 3 e − ,

(6) 2 Al ( O H ) 3 = Al 2 O 3 · 3 H 2 O .

Further, scanning the potential towards a positive direction affects the stability of the formed film and destroys it, leading to an increase in the values of current seen in the curves. The pitting corrosion occurs due to this breakdown of the oxide layer [22,23,24]. The appearance of a hysteresis loop due to the increased current upon reversing the swept potential in the more negative direction confirmed the occurrence of pitting corrosion. It has been reported [3,27,30,31] that chemisorption of Cl− occurs onto the surface of the formed Al2O3 film, breaking it and leading to Al(OH)2Cl2 formation:

(7) Al + 2 Cl − + 2 OH − = Al ( OH ) 2 Cl 2 .

The polarization curve for the sample that was cooled inside the furnace (Figure 1b, sample-2) exhibited almost the same behavior, except that the values of E Corr were less negative, j Corr and R Corr values were lower, while R P was higher, as shown in Table 1. This indicates that cooling the sample in the furnace is more favorable for making the alloy more corrosion-resistant. Also, the CPP curve obtained after cooling the sample in the air (Figure 1c, sample-3) shows the same behavior but with lower corrosion damage, as indicated by the lower value of j Corr and higher value of R P. Finally, quenching the alloy in water (Figure 4d, sample-4) presented the highest R P with the lowest value of a corrosion rate, R Corr. Moreover, the values of E Prot and E Pit recorded the least negative values, as confirmed in Table 1, and indicate that the severity of pitting attack decreases for the treated samples. The CPP results thus provided that the R P value increases and the R Corr value decreases for the tested samples as per the following order: sample-4 > sample-3 > sample-2 > sample-1.

Figure 2 shows the CPP curves for the samples after extending the time to 24 h. The curves of Figure 2 and the parameters presented in Table 1 confirm that exposing to the chloride solution for 24 h decreases the corrosion of all samples. This can be seen by the decrease in the values of j Corr compared to its values when the samples were exposed to the solution for only 1 h. Improving the corrosion resistance for all samples after 24 h immersion is due to the formation of the Al2O3 film that gets thickened with time. The ability of the Al2O3 layer to decrease the dissolution of the surface of the aluminum samples has been proven, as reported before [32,33,34,35]. CPP measurements proved that the resistance of AA6063 alloy to corrosion increases when cooled in the furnace and even more when left to be cooled in air, and the highest effect on the improvement of the resistance against corrosion was obtained by quenching the alloy in water. This agrees with the results obtained by He et al. [18] that the corrosion resistance of the quenched 6063 alloy is higher than the corrosion resistance of the same alloy that was cooled in air.

3.2 Chronoamperometric current–time (CCT) measurements and surface investigation

CCT tests were collected for all samples at −650 mV after their immersion in NaCl solution for 1 and 24 h. The value of constant voltage was chosen at a certain value of the anodic sides for CPP curves to be in the region of the pitting corrosion. The curves of current with time for all samples after immersion for 1 h are depicted in Figure 3. The CCT curves were also collected for the tested samples after 24 h, and the curves are displayed in Figure 4. The CCT curves show that the currents of all samples increased upon application of potential that results from the dissolution of an oxide film(s), which may form onto the surfaces in the presence of the samples in the solution before measurements. These currents decreased again over time due to the stabilization of the surface via the formation of corrosion products on the surface. Accordingly, the influence of the cooling conditions is clear in reducing the absolute current values, where sample-4 showed the lowest current, followed by sample-3, sample-2, and sample-1.

Figure 3 CCT curves gathered at −650 mV for the tested samples ((1) sample-1, (2) sample-2, (3) sample-3, and (4) sample-4) that were exposed to 3.5% NaCl solution for 1 h.
Figure 3

CCT curves gathered at −650 mV for the tested samples ((1) sample-1, (2) sample-2, (3) sample-3, and (4) sample-4) that were exposed to 3.5% NaCl solution for 1 h.

Figure 4 CCT curves gathered at −650 mV for the tested samples ((1) sample-1, (2) sample-2, (3) sample-3, and (4) sample-4) that were exposed to 3.5% NaCl solution for 24 h.
Figure 4

CCT curves gathered at −650 mV for the tested samples ((1) sample-1, (2) sample-2, (3) sample-3, and (4) sample-4) that were exposed to 3.5% NaCl solution for 24 h.

On the other hand, the change in the current with time obtained after 24 h provided a completely different behavior for all tested samples, as shown in Figure 4. The currents obtained from all samples at the initial application of the anodic potential (−650 mV (Ag/AgCl)) were zero because of the complete coverage of the surface of the samples via a stable film of an oxide that is formed during the exposure to the solution. The current then consciously increases as a result of the dissolution of the surface oxide, and pitting corrosion takes place, as aforementioned, by CPP curves and reactions (4)–(7). Furthermore, the highest absolute currents were obtained for the untreated sample-1, while the sample that was cooled in the furnace (sample-2) presented lower absolute currents. Further lower currents were recorded for the sample that was cooled in air (sample-3), and the lowest currents were obtained for the sample that was quenched in water (sample-4). This confirms that the CCT results agree with the data of the polarization measurements.

Figure 5 shows the scanning electron microscopy (SEM) images taken for the surfaces of (a) sample-1, (b) sample-2, (c) sample-3, and (d) sample-4 after performing the chronoamperometric experiments shown in Figure 4. Here, the alloys were immersed for 24 h before being applied (650 mV 3,200 s), and then the surfaces of the alloys were dried and subjected to microscopy. It is seen from Figure 5, image (a), that the surface of the as-received alloy (sample-1) is severely corroded via both uniform and pitting corrosion. This is because of the dissolution of Al from the surface of the alloy, as indicated by Equation (4). The SEM image taken for the alloy that was cooled inside the furnace (sample-2, Figure 5, image (b)) showed a corroded surface but was slightly damaged compared to the surface of sample-1. Cooling the surface in air has a better effect on decreasing the corrosion of AA6063 alloy as the SEM image taken for sample-3 (Figure 5, image (c)) appears to be less deteriorated compared to the surfaces of sample-1 and samples. The highest corrosion resistance and the lowest surface corrosion can be visualized from the surface of sample-4 (Figure 5 (image (d)), which was cooled by quenching in water. The surface investigation by SEM images thus confirms the results of the CPP and CCT that the corrosion resistance of the tested alloy samples increases in the following order: sample-4 > sample-3 > sample-2 > sample-1.

Figure 5 SEM images were obtained for the surface of samples ((a) sample-1, (b) sample-2, (c) sample-3, and (d) sample-4) after performing the chronoamperometric experiments shown in Figure 4.
Figure 5

SEM images were obtained for the surface of samples ((a) sample-1, (b) sample-2, (c) sample-3, and (d) sample-4) after performing the chronoamperometric experiments shown in Figure 4.

3.3 Electrochemical impedance spectroscopy (EIS) measurements

The EIS test was performed to report the impact of the cooling conditions on the passivation of AA6063 alloy’s corrosion in 3.5% NaCl electrolyte. EIS test indicates the corrosion and its control in numerous media [36,37,38,39,40]. The Nyquist plots of the tested samples that were exposed to NaCl solutions for 1 h are presented in Figure 6. The Nyquist plots were also collected after 24 h, and the spectra are displayed in Figure 7. All these data were fitted to a circuit, as shown in Figure 8, that has been used in several research studies [11,12,20,22,35]. Table 2 summarizes the values of the impedance data that are defined as follows: R S = solution resistance, Q = constant phase elements (CPEs), R P1 = first polarization resistance, C dl = double layer capacitance, and R P2 = second polarization resistance. It has been reported that Q (CPEs), the admittance of a CPE, and the impedance, Z CPE, are expressed, respectively, according to the following relations [11,22,41,42]:

(8) Z CPE = [ Q ( 2 π fi ) n ] − 1 ,

(9) Y CPE = − Y 0 ( j ω ) n ,

(10) Z CPE = − ( 1 / Y 0 ) ( j ω ) n .

Figure 6 Nyquist plots obtained for the immersed samples ((1) sample-1, (2) sample-2, (3) sample-3, and (4) sample-4) in NaCl solution for 1 h.
Figure 6

Nyquist plots obtained for the immersed samples ((1) sample-1, (2) sample-2, (3) sample-3, and (4) sample-4) in NaCl solution for 1 h.

Figure 7 Nyquist plots obtained for the immersed samples ((1) sample-1, (2) sample-2, (3) sample-3, and (4) sample-4) in NaCl solution for 24 h.
Figure 7

Nyquist plots obtained for the immersed samples ((1) sample-1, (2) sample-2, (3) sample-3, and (4) sample-4) in NaCl solution for 24 h.

Figure 8 The circuit used in fitting the EIS experiments.
Figure 8

The circuit used in fitting the EIS experiments.

Table 2

EIS data of AA6063 samples after 1 and 24 h exposure to NaCl solution

Sample R S/Ω/cm−2 Q R P1/Ω/cm−2 C dl/F/cm2 R P2/Ω/cm−2
µYQ/F/cm2 N
Sample-1 (1 h) 11.50 ± 0.50 0.325 ± 0.05 0.77 1,155 ± 5 0.000182 7,084 ± 6
Sample-2 (1 h) 12.07 ± 0.13 0.281 ± 0.09 0.82 1,202 ± 8 0.000196 7,231 ± 4
Sample-3 (1 h) 14.98 ± 0.20 0.256 ± 0.04 0.80 1,632 ± 3 0.000179 8,560 ± 5
Sample-4 (1 h) 15.09 ± 0.11 0.237 ± 0.03 0.8 2,519 ± 1 0.000127 9,687 ± 3
Sample-1 (24 h) 16.81 ± 0.19 0.166 ± 0.04 0.88 3,018 ± 2 0.000230 15,450 ± 5
Sample-2 (24 h) 17.76 ± 0.24 0.181 ± 0.09 0.88 4,086 ± 4 0.000157 16,205 ± 5
Sample-3 (24 h) 16.0 ± 0.32 0.209 ± 0.11 0.83 6,276 ± 04 0.000073 22,290 ± 5
Sample-4 (24 h) 16.56 ± 0.14 0.142 ± 0.08 0.88 6,731 ± 4 0.000069 24,089 ± 1

All Nyquist spectra (Figure 6) show a semicircle and segment. The lowest semicircle and the shortest segment were displayed for sample-1 (plot 1, which represents the as-received alloy). Cooling the alloy inside the furnace (spectrum 2, sample-2) allows the sample to be slightly passivated, as indicated by the slight increase of the semicircle and accompanying segment. Allowing the alloy to be cooled in air (plot 3, sample-3) further increases its passivity, which is revealed by the increase of both the diameter of the semicircle and the length of its segment. The widest semicircle with the longest segment was recorded for the alloy that was quenched in water (sample-4), as shown in plot 4 of Figure 6. This behavior proves that changing the cooling condition can decrease the corrosion of the AA6063 alloy and improve its passivation in the chloride test electrolyte.

The Nyquist spectra obtained after 24 h, Figure 7, are greatly different from those obtained after only 1 h and are shown in Figure 6. A longer immersion time remarkably increased the values of the obtained real and imaginary resistances, reduced the diameter of the semicircle, and elongated the length of the segment. Only sample-1 shows a wide diameter and slightly short segment, indicating that this sample has the least corrosion resistance. Cooling the alloy in the furnace reflected on a minute semicircle and a longer segment, revealing a higher corrosion resistance. Treating the alloy to cool in air further improved the resistance to corrosion, as indicated by the long segment. The highest effect of the heat treatment was recorded for the alloy that was quenched in water as it provided the longest segment, confirming that sample-4 has the highest corrosion resistance.

The Nyquist spectra of Figures 6 and 7 were supported by the impedance elements, as shown in Table 2. Here, the surface and polarization resistances (R S, R P1, and R P2) were the lowest for sample-1 and the highest for the sample that was quenched in water (sample-4) both after 1 and 24 h. On the other hand, Y Q and C dl recorded decreased values with this trend, where sample-1 has the highest values, but the quenched sample-4 has the lowest ones. The Q with its “n” values near unity and the presence of C dl indicate the presence of double-layer capacitors that have some pores. The increase of R S, R P1, and R P2 values and the decrease in Q as well as C dl refer to the decrease in the severity of corrosion.

To further confirm the corrosion of AA6063 alloy after being cooled in different ways, the Bode impedance (|Z|) of the interface and the phase angle (Φ) degree were considered. The plots of (a) |Z| and (b) Φ for all samples after 1 and 24 h exposure to NaCl solutions are depicted in Figures 9 and 10, respectively. These plots showed that the as-received sample-1 has the lowest |Z| values, particularly in the region of low frequency, and the lowest maximum value for Φ. The value of |Z| and the maximum value of Φ increased with changing the cooling method. The |Z| and the maximum Φ values increased in the following order: sample-4 > sample-3 > sample-2 > sample-1. The same order with even increased values of |Z| and Φ were also obtained for the AA6063 samples after being immersed for 24 h, as shown in Figure 10. The increase of |Z| values increases the passivity for metals and samples. The increase in the maximum values of Φ also confirms the increased corrosion resistance [39,40]. This behavior of Bode |Z|, shown in Figures 9 and 10, confirms the results obtained by the Nyquist spectra of Figures 6 and 7. The increase of the maximum value of Φ also confirms the same principle.

Figure 9 Bode (a) |Z| and (b) Φ plots for the AA6063 samples after 1 h in the chloride solution.
Figure 9

Bode (a) |Z| and (b) Φ plots for the AA6063 samples after 1 h in the chloride solution.

Figure 10 Bode (a) |Z| and (b) Φ plots for the AA6063 samples after 24 h in the chloride solution.
Figure 10

Bode (a) |Z| and (b) Φ plots for the AA6063 samples after 24 h in the chloride solution.

4 Conclusion

An AA6063 Al alloy was heat treated under four different cooling methods. The first alloy sample was used as received, the second one was cooled inside the furnace, the third sample was left to cool in the air, and the fourth alloy sample was cooled by quenching in water. The impact of these cooling methods on the corrosion behavior of various AA6063 Al alloy samples was carried out after immersing in 3.5% NaCl solution for 1 and 24 h. Several electrochemical techniques, such as the polarization CPP, the chronoamperometric CCT at −650 mV, and the impedance EIS measurements, were employed to study the corrosion of the treated samples. The CPP experiments indicated that the values of R Corr and R P vary with changing the cooling method for the AA6063 alloy, where the as-received (the first) alloy showed the lowest R P and the highest R Corr values. Cooling the alloy inside the furnace (the second sample) slightly decreased its R Corr and slightly enhanced its R P value. Exposure to ambient air during cooling (the third alloy sample) further increased the R P value, while quenching the sample in water resulted in the highest value of R P and the lowest value of R Corr. The EIS data confirmed the CPP obtained results that varying the cooling conditions can reduce the corrosion via reducing the measured corrosion current, which increases the corrosion resistance. The change in the chronoamperometric current over time at −650 mV (CCT) indicated variations in the intensity of pitting attacks corresponding to the cooling method, which was confirmed by the surface morphology images taken for the surfaces by SEM. Overall, the results indicated that the corrosion resistance of AA6063 alloy follows the order: quenched in water > cooled in air > cooled inside the furnace > the as-received alloy. The outcome of this work enhances the corrosion resistance of the currently tested alloy samples in different applications. This work also opens a new window for applying the cooling conditions to reduce the corrosion of different alloys and composites in corrosive media.

Acknowledgments

The authors acknowledge the researchers supporting project number [RSPD2024R597], King Saud University, Riyadh, Kingdom of Saudi Arabia.

  1. Funding information: This research was funded by King Saud University-Project number (RSPD2024R597).

  2. Author contributions: All authors have accepted responsibility for the entire content of this manuscript and consented to its submission to the journal, reviewed all the results and approved the final version of the manuscript. E-SMS, IAA, and ATA: investigation, conceptualization, methodology, data curation, validation, visualization, formal analysis, writing, supervision, and project administration, writing original draft; E-SMS and IAA: review and editing; IAA: funding acquisition.

  3. Conflict of interest: Authors state no conflict of interest.

  4. Data availability statement: Not applicable.

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Received: 2024-04-08
Revised: 2024-07-16
Accepted: 2024-08-05
Published Online: 2024-08-27

© 2024 the author(s), published by De Gruyter

This work is licensed under the Creative Commons Attribution 4.0 International License.

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https://doi.org/10.1515/secm-2024-0031
Keywords for this article
AA6063 aluminum alloy; heat treatment; corrosion; potentiodynamic polarization; impedance spectroscopy; surface investigation
Creative Commons
BY 4.0

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