Corrosion resistance and passivation behavior of 3004 AlMnMg and 4044AlSi aluminum alloys in acid-chloride electrolytes

Corrosion resistance of 3004 and 4044 aluminium alloys (3004Al and 4044Al) in neutral chloride (0.5%-4.5% concentration), sulphate (0.00625M-0.1 M concentration), and chloride-sulphate (0.00625 M H2SO4/0.5%-4.5% chloride concentration) solutions was studied with potentiodynamic polarization, open circuit potential, cyclic polarization, and optical microscopy. Results show 4044Al exhibited higher resistance to general corrosion while 3004Al was more resistant to localized corrosion. Corrosion of 4044Al decreases with increase in chloride concentration while 3004 Al increases. Corrosion rate values for 3004Al and 4044Al in sulphate solution were generally similar between 0.061-0.395 mm y-1 and 0.168-0.213 mm y-1, respectively. In chloride-sulphate solution, corrosion rate of 3004Al increased from 0.130 mm y-1 to 1.563 mm y-1 at peak chloride concentration whereas the corrosion rate of 4044Al is near constant. The passive film on 4044Al is found to weaken significantly with increase in chloride concentration. Passivation values varied from 0.39 V at 0.5% chloride concentration to 0.01 V at 4.5% concentration while the potential at which stable pitting occurred increased. The passivation range values for 3004Al are relatively stable with respect to chloride concentration. Results from cyclic polarization experiments show the deterioration rate of both alloys in NaCl solution is subject to chloride concentration. The results show the alloys corrode at all NaCl concentrations (0.5%-4.5%) with the lowest pitting corrosion risk in 0.5% and 1.5%NaCl solutions. The highest pitting corrosion risk of the alloys occurred in 3.5% NaCl solution. Significant localized morphological deterioration is visible throughout the entirety of 4044Al relative to the adjacent Al alloy matrix compared to total surface deterioration on 3004Al.