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<p>AA7075 is an alloy of interest for structural applications, especially in the aerospace industry. AA7XXX series of alloys, and AA7075 in particular, are known to have a tendency for crack formation when anodized in sulfuric acid electrolyte. Alternate electrolytes like chromic acid and phosphoric acid result in smaller thickness and enlarged pores, respectively, which may be inadequate from corrosion resistance and hardness point of view. Here we report a systematic study conducted to capture the progressive deterioration in anodized aluminum oxide (AAO) film with anodization time. The study involved sample preparation, preparation of cut sections, anodization thickness mapping, SEM and XRD analysis. Absence of crack formation on AAO layer could be ensured by following an anodization duration of 20&#xa0;min or lesser which resulted in a AAO thickness less than 15&#xa0;µm. Sealing in boiling hot water had no role in crack initiation, formation or progression. The study was motivated by the progressive degradation resulting in high-pressure gaseous helium leakage noticed after actuations through aerospace valve bodies fabricated using anodized AA7075-T7352.</p>

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Effect of Anodization Duration on Crack-Free Anodized Aluminum Oxide Formation in Sulfuric Acid Anodized AA7075-T7352 Alloy for Aerospace Applications

  • 期刊论文

  • 发表日期：

    2026年5月29日

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  • Subrata Chakrabarti,
  • Santosh Kumar Tamang,
  • Arti Yadav,
  • Lagudu Yerrinaidu,
  • K. Jalaja,
  • T. Sheeja,
  • N. Gopakumar,
  • T. M. Philip,
  • D. Venkittaraman,
  • A. Manimaran,
  • Balaram Sahoo,
  • M. S. Bobji

摘要

AA7075 is an alloy of interest for structural applications, especially in the aerospace industry. AA7XXX series of alloys, and AA7075 in particular, are known to have a tendency for crack formation when anodized in sulfuric acid electrolyte. Alternate electrolytes like chromic acid and phosphoric acid result in smaller thickness and enlarged pores, respectively, which may be inadequate from corrosion resistance and hardness point of view. Here we report a systematic study conducted to capture the progressive deterioration in anodized aluminum oxide (AAO) film with anodization time. The study involved sample preparation, preparation of cut sections, anodization thickness mapping, SEM and XRD analysis. Absence of crack formation on AAO layer could be ensured by following an anodization duration of 20 min or lesser which resulted in a AAO thickness less than 15 µm. Sealing in boiling hot water had no role in crack initiation, formation or progression. The study was motivated by the progressive degradation resulting in high-pressure gaseous helium leakage noticed after actuations through aerospace valve bodies fabricated using anodized AA7075-T7352.