<p>High-pressure die casting is extensively used in the automotive industry to produce complex Al alloy components. Although die cavity lubrication is applied between each production casting to enable easy component release and die tool thermal balance, it imparts unwanted residue on the as-cast surface. This study determines the extent to which the as-cast surface affects localized corrosion of A365-T7 high-pressure die castings by comparing the as-cast (AC) surface with a mechanically abraded (MA) counterpart. Starting surfaces were characterized in cross section for composition and structure differences using light optical and electron microscopy. Localized corrosion resistance was determined using electrochemical (cyclic potentiodynamic anodic polarization and galvanostatic anodic polarization) and bulk immersion (mass loss) techniques. The mode and extent of anodic dissolution were determined using surface profilometry and electron microscopy of surfaces in cross section. The results show that the AC surface is less prone to localized corrosion than the MA surface, despite being significantly more heterogeneous in topology and composition. A different metal oxide layer composition is believed to be the critical factor controlling the observed difference in localized corrosion resistance. The working hypothesis is one that involves the formation of a less aggressive occluded electrolyte at a localized corrosion initiation site on the AC surface resulting from the presence of dissolved Mg<sup>2+</sup>cations.</p> Graphical Abstract <p></p>

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Localized Corrosion Resistance of A365-T7 High Pressure Die Casting Surfaces

  • A. C. Abraham,
  • A. Gonzalez-Villarreal,
  • A. Lombardi,
  • G. Byczynski,
  • S. Shankar,
  • J. R. Kish

摘要

High-pressure die casting is extensively used in the automotive industry to produce complex Al alloy components. Although die cavity lubrication is applied between each production casting to enable easy component release and die tool thermal balance, it imparts unwanted residue on the as-cast surface. This study determines the extent to which the as-cast surface affects localized corrosion of A365-T7 high-pressure die castings by comparing the as-cast (AC) surface with a mechanically abraded (MA) counterpart. Starting surfaces were characterized in cross section for composition and structure differences using light optical and electron microscopy. Localized corrosion resistance was determined using electrochemical (cyclic potentiodynamic anodic polarization and galvanostatic anodic polarization) and bulk immersion (mass loss) techniques. The mode and extent of anodic dissolution were determined using surface profilometry and electron microscopy of surfaces in cross section. The results show that the AC surface is less prone to localized corrosion than the MA surface, despite being significantly more heterogeneous in topology and composition. A different metal oxide layer composition is believed to be the critical factor controlling the observed difference in localized corrosion resistance. The working hypothesis is one that involves the formation of a less aggressive occluded electrolyte at a localized corrosion initiation site on the AC surface resulting from the presence of dissolved Mg2+cations.

Graphical Abstract