Corrosion behavior of alumina-aluminum and silicon carbide-aluminum metal-matrix composites

Abstract

Particle-reinforced, aluminum-based metal-matrix composites (MMCs) are being considered for a range of applications. Their mechanical properties have been investigated in detail, but more information about their corrosion behavior is needed. The influences of alloy composition; particle characteristics such as composition, size, volume fraction, and pretreatment; and composite post-treatment on the aqueous corrosion behavior of aluminum-matrix composites prepared by the melt stirring process were studied. Corrosion tests consisted of prolonged immersion and anodic polarization measurements in sodium chloride (NaCl) solutions. The difference between the corrosion potential (Ecorr) and the pitting potential (Ep) was lowered from ~ 500 mVSCE in deaerated NaCl to 100 mVSCE in aerated NaCl. Particle addition affected Ep but not Ecorr. Immersion test data revealed significant specimen weight loss for the composites resulting from formation of pits or microcrevices in the matrix near the particle-matrix interface and from particle dropout. Pits in the silicon carbide (SiC) composites were deeper than those in the alumina (Al2O3) composites, probably because the SiC particles acted as efficient cathodic sites. Pit initiation and propagation occurred at weak spots in the air-formed film, corresponding to phase discontinuities and second-phase particles and to oxygen reduction at the particles or precipitates. Anodization and ceria (CeO2) coatings improved corrosion resistance of the composites.