Corrosion Performance of MIG Welded Cu-lean AA7xxx Alloys

Abstract

An investigation was undertaken to better understand the corrosion behaviour of dissimilar welded Cu-lean AA7003 and AA7108 extrusions. The major variables under study were the heat-treated condition (as-welded T6 vs. as-welded T6+Paint Bake (PB)), extrusion alloy Cu composition (AA7003 vs. AA7108), weld filler composition (ER4043 vs. ER5356), weld joint geometry (lap-joint vs. T-joint), and weld direction with respect to extrusion direction (parallel (═) vs. perpendicular (┴)). The corrosion behaviour of the various weld configurations under investigation was observed using an ASTM standard practice for modified salt spray testing (ASTM G85-A2), a GM worldwide engineering standard for cyclic corrosion testing (GMW-14872), and potentiodynamic polarization measurements. The effect of exposure to GMW-14872 on the tensile-shear behaviour of the various weld configurations under study was also investigated using a custom tensile jig. Examination post exposure to ASMT G85-A2 revealed the presence of differing pitting corrosion morphologies between AA7003 and AA7108. Due to increased Cu-content, AA7003 displayed deep pitting corrosion which penetrated the entirety of the dynamically recrystallized top surface layer and reached the fine-grained interior. Shallow pitting of the recrystallized surface layer was observed on AA7108, with very few penetration sites that reached the underlying fine-grained interior. No difference in corrosion behaviour was observed between the heat affected zone (HAZ) and unaffected base alloy of welded AA7003 and AA7108, also consistent with potentiodynamic polarization results. However, the HAZ displayed dual corrosion bands separated by a thin band of unattacked alloy; a result of distinct local microstructural changes induced by thermal cycling from welding. Tensile-shear testing revealed four types of observed fracture modes: shear across the weld throat, fracture along the AA7xxx/ER5356 interface, fracture along the AA6063/ER5356 interface and fracture in the HAZ of AA7xxx. Little to no corrosion was observed on weld configurations exposed to GMW-14872, resulting in no differences in the tensile-shear behaviour of exposed and unexposed weld configurations. Large variations observed in the tensile-shear results were a result of numerous weld defects.