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<p>The present study investigates the correlation between microstructure evolution and marine corrosion behavior of friction stir welded (FSW) AA6063 Al–Mg–Si alloy joints for potential marine structural applications. Defect-free joints were fabricated using optimized FSW parameters, producing distinct weld regions such as Base Metal (BM), Thermo-Mechanically Affected Zone (TMAZ), Heat-Affected Zone (HAZ), and Nugget Zone (NZ). Optical microscopy and SEM–EDS analyses revealed significant grain refinement in the NZ (~ 4.2&#xa0;µm) with uniformly distributed fine Mg₂Si precipitates, whereas the HAZ exhibited severe grain coarsening (~ 61.4&#xa0;µm) and over-aged precipitates. Marine corrosion performance was evaluated through 30-day atmospheric exposure near the sea, immersion testing in 3.5&#xa0;wt.% NaCl solution, and Tafel polarization analysis. Among all weld regions, the NZ demonstrated superior corrosion resistance with the lowest corrosion rate (0.004258&#xa0;mpy), which was approximately 51.6% lower than that of the HAZ (0.008792&#xa0;mpy). The enhanced corrosion resistance of the NZ was attributed to refined grain structure, homogeneous precipitate distribution, and improved passive film stability. In contrast, the HAZ exhibited severe localized corrosion due to coarse grains and galvanic precipitates. The present work highlights the practical significance of FSW in developing corrosion-resistant aluminum joints for long-term marine structural applications.</p>

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Correlation between Microstructure Evolution and Marine Corrosion in Friction Stir Welded Al–Mg–Si Alloys

  • 期刊论文

  • 发表日期：

    2026年5月31日

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  • Mukuloth Srinivasnaik,
  • Korada Santarao,
  • Moturu Seshu,
  • Kannam Sree Sruthi,
  • Anusha Mylavarapu,
  • Peyyala Pramod Kumar,
  • K. Rajesh

摘要

The present study investigates the correlation between microstructure evolution and marine corrosion behavior of friction stir welded (FSW) AA6063 Al–Mg–Si alloy joints for potential marine structural applications. Defect-free joints were fabricated using optimized FSW parameters, producing distinct weld regions such as Base Metal (BM), Thermo-Mechanically Affected Zone (TMAZ), Heat-Affected Zone (HAZ), and Nugget Zone (NZ). Optical microscopy and SEM–EDS analyses revealed significant grain refinement in the NZ (~ 4.2 µm) with uniformly distributed fine Mg₂Si precipitates, whereas the HAZ exhibited severe grain coarsening (~ 61.4 µm) and over-aged precipitates. Marine corrosion performance was evaluated through 30-day atmospheric exposure near the sea, immersion testing in 3.5 wt.% NaCl solution, and Tafel polarization analysis. Among all weld regions, the NZ demonstrated superior corrosion resistance with the lowest corrosion rate (0.004258 mpy), which was approximately 51.6% lower than that of the HAZ (0.008792 mpy). The enhanced corrosion resistance of the NZ was attributed to refined grain structure, homogeneous precipitate distribution, and improved passive film stability. In contrast, the HAZ exhibited severe localized corrosion due to coarse grains and galvanic precipitates. The present work highlights the practical significance of FSW in developing corrosion-resistant aluminum joints for long-term marine structural applications.