Effect of rotational speed on the microstructure and corrosion resistance of 2219 aluminum alloy manufactured by additive friction stir deposition

Abstract

The 2219 aluminum alloy is widely utilized in critical structural components owing to its superior overall performance, while additive friction stir deposition (AFSD) exhibits potential for large-scale manufacturing. However, research on the corrosion behavior of AFSD-fabricated materials remains limited, and the influence of process parameters on corrosion mechanisms requires further exploration. This study compares the microstructure and corrosion resistance of different deposition layers in 2219 aluminum alloy fabricated by AFSD at rotational speeds of 400 rpm and 700 rpm. Higher rotational speed (700 rpm) generated greater thermal input and plastic deformation, promoting dynamic recrystallization and leading to larger grain sizes (bottom layer: 3.40 μm [400 rpm] vs. 3.83 μm [700 rpm]; top layer: 2.50 μm [400 rpm] vs. 3.01 μm [700 rpm]) and increased high-angle grain boundaries (bottom layer: 71.5% [400 rpm] vs. 75.2% [700 rpm], top layer: 57.3% [400 rpm] vs. 63.0% [700 rpm]). The bottom layer, experiencing more thermal cycles, showed further grain growth and resulted in larger grain sizes. At 700 rpm, greater precipitation of the Al2Cu phase increased the number of micro-galvanic couples between precipitates and the aluminum matrix, accelerating corrosion. Conversely, greater thermal input in the bottom layer promoted Cu dissolution and reduced precipitate formation, improving corrosion resistance compared to the top layer. Consequently, the bottom layer processed at 400 rpm exhibited the optimal corrosion resistance, with the highest Rct value of 4.17 × 103 Ω·cm2. As the rotational speed decreased, the corrosion resistance was enhanced.

Keywords

Rotational speed / Microstructure / Corrosion / Additive friction stir deposition

Funding

This work was supported by the National Key R&D Program of China (2023YFE0205300), the Guangdong Basic and Applied Basic Research Foundation (2021B1515130009), and the Fundamental Research Funds for the Central Universities (FRF-BD-25-044), and the National Natural Science Foundation of China (No. 52201062).

Conflict of Interest

Qian Qiao, Dawei Guo, and Lap Mou Tam are employees of IDQ Science and Technology Development (Hengqin, Guangdong) Co., Ltd., while Zhixiong Zhu and Yongyong Lin are employees of Aerospace Engineering Equipment (Suzhou) Co., Ltd.; however, they were not involved in any activities that could constitute a conflict of interest in relation to this study. Other authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.

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