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<p>The present work introduces a novel systematic investigation of the combined effects of environmental parameters on gas tungsten arc welded AA5052 aluminium alloy joints using ER4043 filler material under salt spray conditions. Through rigorous statistical analysis using response surface methodology, this study uniquely quantifies the individual and interactive contributions of pH value (6–7.2), exposure time (168–504&#xa0;h), and Cl − concentration (0.2–1&#xa0;M) on weldment corrosion resistance. The research reveals that exposure time exhibits the strongest influence (48.24% contribution) with corrosion rates increasing from 14.93 to 19.94&#xa0;mm/year as exposure extends from 168 to 504&#xa0;h. Chloride concentration demonstrates the second highest impact (26.07% contribution), showing minimal effect between 0.2 and 0.6&#xa0;M but accelerating corrosion significantly at 1&#xa0;M. pH value shows the least influence (1.05% contribution) with optimal corrosion resistance achieved at pH 6.6. Surface analysis through SEM revealed predominantly pitting-type corrosion, with pit morphology varying significantly based on parameter combinations—from shallow pits under moderate conditions to continuous wavy patterns under aggressive conditions. The study establishes optimal processing parameters (pH 6.6, 336&#xa0;h exposure, 1&#xa0;M Cl −) achieving a minimum corrosion rate of 14.02&#xa0;mm/year.</p>

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Corrosion Behaviour of AA5052 Alloy Weldments Under Salt Spray Environment

  • 期刊论文

  • 发表日期：

    2025年3月29日

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  • S. Omprakasam,
  • R. Raghu,
  • R. Sudhakar,
  • R. Vijaya Kumar

摘要

The present work introduces a novel systematic investigation of the combined effects of environmental parameters on gas tungsten arc welded AA5052 aluminium alloy joints using ER4043 filler material under salt spray conditions. Through rigorous statistical analysis using response surface methodology, this study uniquely quantifies the individual and interactive contributions of pH value (6–7.2), exposure time (168–504 h), and Cl − concentration (0.2–1 M) on weldment corrosion resistance. The research reveals that exposure time exhibits the strongest influence (48.24% contribution) with corrosion rates increasing from 14.93 to 19.94 mm/year as exposure extends from 168 to 504 h. Chloride concentration demonstrates the second highest impact (26.07% contribution), showing minimal effect between 0.2 and 0.6 M but accelerating corrosion significantly at 1 M. pH value shows the least influence (1.05% contribution) with optimal corrosion resistance achieved at pH 6.6. Surface analysis through SEM revealed predominantly pitting-type corrosion, with pit morphology varying significantly based on parameter combinations—from shallow pits under moderate conditions to continuous wavy patterns under aggressive conditions. The study establishes optimal processing parameters (pH 6.6, 336 h exposure, 1 M Cl −) achieving a minimum corrosion rate of 14.02 mm/year.