<p>Aluminum alloys are widely used in aerospace and marine engineering but suffer from pitting and intergranular corrosion in Cl<sup>-</sup> and SO<sub>2</sub> containing environments. Chemical oxidation can form protective oxide films, yet structural defects or excessive thickness often lead to premature failure. A dense anti-corrosion nano-conductive film (ANCF) was in-situ synthesized on an aluminum alloy surface. The effects of reaction time on microstructure, composition, and corrosion resistance were systematically studied. The optimized ANCF-3 film exhibited an amorphous or nanocrystalline-amorphous composite structure with a contact angle of 92.15°. The corrosion rate was reduced to 6.64 × 10<sup>-5</sup> mm/year, which indicated that the ANCF significantly improved the corrosion resistance of aluminum alloys. These improvements were mainly attributed to the synergistic protective mechanism between the hydrophobic surface and the multilayer structure of ANCF: the ANCF surface achieved transition from hydrophilic to hydrophobic, which not only effectively inhibited the adhesion and wetting of water molecules and corrosive media but also reduced their effective contact area with the film. Furthermore, the multilayer structure inhibited the diffusion of aggressive substances toward the aluminum substrate. This study provides a technical foundation for optimizing chemical oxidation processes and offers significant potential for extending aluminum alloy applications in extreme environments.</p>

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In Situ Synthesis of Oxide Film on Aluminum Alloy for Enhanced Corrosion Resistance

  • Zongxi Liu,
  • Benhong Ouyang,
  • Baozhi Zang,
  • Rong Jing,
  • Kai Kang,
  • Gang Li

摘要

Aluminum alloys are widely used in aerospace and marine engineering but suffer from pitting and intergranular corrosion in Cl- and SO2 containing environments. Chemical oxidation can form protective oxide films, yet structural defects or excessive thickness often lead to premature failure. A dense anti-corrosion nano-conductive film (ANCF) was in-situ synthesized on an aluminum alloy surface. The effects of reaction time on microstructure, composition, and corrosion resistance were systematically studied. The optimized ANCF-3 film exhibited an amorphous or nanocrystalline-amorphous composite structure with a contact angle of 92.15°. The corrosion rate was reduced to 6.64 × 10-5 mm/year, which indicated that the ANCF significantly improved the corrosion resistance of aluminum alloys. These improvements were mainly attributed to the synergistic protective mechanism between the hydrophobic surface and the multilayer structure of ANCF: the ANCF surface achieved transition from hydrophilic to hydrophobic, which not only effectively inhibited the adhesion and wetting of water molecules and corrosive media but also reduced their effective contact area with the film. Furthermore, the multilayer structure inhibited the diffusion of aggressive substances toward the aluminum substrate. This study provides a technical foundation for optimizing chemical oxidation processes and offers significant potential for extending aluminum alloy applications in extreme environments.