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<p>Hybrid aluminum matrix composites are increasingly used in aerospace and automotive industries due to their low density, high strength, and improved corrosion resistance. However, achieving uniform reinforcement dispersion with stable electrochemical performance remains challenging. In this study, a novel Al-based hybrid composite reinforced with 3&#xa0;wt% tungsten carbide (WC) and 3&#xa0;wt.% molybdenum disulfide (MoS<sub>2</sub>) was fabricated via accumulative roll bonding (ARB) at room temperature to enhance microstructural uniformity and corrosion behavior. SEM, EDS, and XRD analyses confirmed uniform distribution of reinforcements and significant grain refinement, reducing cryallite size from 420 (1<sup>st</sup> cycle) to 151&#xa0;nm (7<sup>th</sup> cycle). Electrochemical tests in 3.5&#xa0;wt% NaCl solution revealed direction-dependent corrosion behavior: in the transverse direction, E<sub>corr</sub> improved by ~ 26% (–0.85&#xa0;V to –0.627&#xa0;V), while i<sub>corr</sub> increased due to galvanic coupling; in the normal direction, corrosion resistance decreased after the 5th cycle as reinforcement particles disrupted the passive layer, increasing corrosion rate by ~ 5600% (from 0.0076 to 0.435&#xa0;mm&#xa0;yr<sup>−1</sup>). These findings demonstrate the potential of ARB processing to develop ultrafine Al/WC/MoS<sub>2</sub> hybrid composites with tailored corrosion properties for structural applications in aggressive environments.</p>

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Fabrication and Characterization of Al/WC/MoS2 Hybrid Composite via Accumulative Roll Bonding: Microstructural Evolution, and Corrosion Behavior

  • 期刊论文

  • 发表日期：

    2025年11月18日

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  • Morteza Alizadeh,
  • Mahdieh Oskouei,
  • Shima Pashangeh,
  • Mamdouh I. Elamy

摘要

Hybrid aluminum matrix composites are increasingly used in aerospace and automotive industries due to their low density, high strength, and improved corrosion resistance. However, achieving uniform reinforcement dispersion with stable electrochemical performance remains challenging. In this study, a novel Al-based hybrid composite reinforced with 3 wt% tungsten carbide (WC) and 3 wt.% molybdenum disulfide (MoS2) was fabricated via accumulative roll bonding (ARB) at room temperature to enhance microstructural uniformity and corrosion behavior. SEM, EDS, and XRD analyses confirmed uniform distribution of reinforcements and significant grain refinement, reducing cryallite size from 420 (1st cycle) to 151 nm (7th cycle). Electrochemical tests in 3.5 wt% NaCl solution revealed direction-dependent corrosion behavior: in the transverse direction, Ecorr improved by ~ 26% (–0.85 V to –0.627 V), while icorr increased due to galvanic coupling; in the normal direction, corrosion resistance decreased after the 5th cycle as reinforcement particles disrupted the passive layer, increasing corrosion rate by ~ 5600% (from 0.0076 to 0.435 mm yr−1). These findings demonstrate the potential of ARB processing to develop ultrafine Al/WC/MoS2 hybrid composites with tailored corrosion properties for structural applications in aggressive environments.