Effects of TiC and Ni reinforcements on the microstructure, corrosion resistance and wear behaviour of AA6061 matrix composite

This study investigates the corrosion resistance and wear behaviour of aluminium matrix composites (AMCs) manufactured through the ultrasonic-assisted stir-casting technique. These composites were synthesized by introducing titanium carbide (TiC) and nickel (Ni) into aluminium alloys (AA6061). The X-ray diffraction results confirmed the presence of α-Al, TiC and Al₃Ni phases within the composites. Microstructural examination demonstrated an uniform dispersion of TiC particles and dispersion of Al₃Ni along grain boundaries. To evaluate the corrosion behaviour, samples were subjected to immersion tests and electrochemical techniques, including potentiodynamic polarization and electrochemical impedance spectroscopy (EIS), in a 3.5 wt% NaCl solution. Immersion tests indicated that the composites exhibited slower dissolution rates than base AA6061 alloys. Potentiodynamic polarization results revealed that the inclusion of TiC and Ni reinforcements enhanced corrosion resistance, with TiC having a more pronounced influence. The EIS tests suggested that the composites had higher charge-transfer resistance than AA6061 alloys. After conducting corrosion tests, scanning electron microscope (SEM) images of the base AA6061 alloys unveiled the presence of deep pits but the inclusion of reinforcements resulted in the shallow pits. In addition, Vickers hardness tests and pin-on-disc wear tests were conducted to investigate hardness and wear properties. Notably, hybrid composites containing 3% TiC and 3% Ni exhibited a substantial 42.18% increase in hardness as compared to the base alloy. These hybrid composites also demonstrated superior wear resistance, with a wear rate that was 58.6% lower compared to AA6061 alloy and 41% less than that of the 3% Ni-reinforced composite.