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Influence of medium- and high-entropy alloy fillers on microstructures and corrosion behaviour of AA5083 plates joined by GTAW process

  • Metals & corrosion
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Abstract

The impact of medium- and high-entropy alloy fillers (4E MEA- Al0.25Fe0.25Ni0.25Cu0.25, and 5E HEA-Al0.20Fe0.20Ni0.20Cu0.20Ti0.20) on the microstructures and corrosion behaviour of AA5083 plates, joined through the GTAW process, is investigated. MEA and HEA fillers were fabricated using the CCW method, and ER5356 filler was used for comparison. This study delves into the alloy fillers’ influence on the resultant microstructural characteristics and corrosion resistance of the welded joints. XRD results on weld samples showcased the presence of FCC and BCC phases. The weldment EBSD data revealed unique grain morphologies: long columnar grains, coarse grains, and fine equiaxed grains in WZ, HAZ, and BM, respectively. Microstructural investigations of the weldment revealed heterogeneous structures with finely distributed grains and strong bonding between the AA5083 base metal and filler wires, influenced by constitutional elements. MEA and HEA weldments showed no intermetallic compounds or precipitates. In the ambient temperature potentiodynamic polarisation test, HEA’s polarisation resistance was 3.76 times greater, while MEA’s was 3.15 times higher than ER5356. The higher corrosion resistance is due to grain refinement, increased grain boundaries, and the formation of a strong passive film. Conversely, in the higher-temperature corrosion experiment, the mass loss for the 5E-HEA and MEA weldments was 4.87 and 3.09 times lower than that of the ER5356 weldments. The corroded surface morphology revealed that the ER5356 weldment had deeper pits, while the MEA and 5E-HEA weldments had pits of smaller sizes. The formation of oxidation film layers on the corroded surface improves the corrosion resistance. X-ray photoelectron spectroscopy (XPS) findings showed metal oxide layer depositions for all the weldments. Researchers observed that equimolar MEA and HEA filler wires can increase durability and be employed in shipbuilding sectors.

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Abbreviations

GTAW:

Gas Tungsten Arc Welding

EBSD:

Electron Backscatter Diffraction

4E MEA:

Four Elements Medium-Entropy Alloy

AFM:

Atomic Force Microscopy

5E HEA:

Five Elements High-Entropy Alloy

AAs:

Aluminium alloys

CCW:

Combined Cable Wire

XPS:

X-ray photoelectron spectroscopy

XRD:

X-ray Diffraction

SS:

Solid Solution

FCC:

Face-Centred Cubic

WZ:

Weld zone

BCC:

Body-Centred Cubic

HAZ:

Heat-Affected Zone

AAs:

Aluminium Alloys

OES:

Optical Emission Spectrometer

BM:

Base Metal

SEM:

Scanning Electron Microscope

OM:

Optical Microstructures

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Acknowledgements

The corrosion equipment was financially supported by the DST—Science and Engineering Research Board (SERB). Corrosion tests were conducted in this study.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Karpagam Institute of Technology, Coimbatore, India

    K. Kaviyarasan

  2. Department of Mechanical Engineering, Sri Krishna College of Engineering and Technology, Coimbatore, India

    R. Soundararajan & A. Sathishkumar

  3. Department of Mechanical Engineering, College of Engineering, Qassim University, Buraydah, 51452, Saudi Arabia

    S. Sivasankaran

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  1. K. Kaviyarasan
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  2. R. Soundararajan
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  3. S. Sivasankaran
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  4. A. Sathishkumar
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Contributions

KK performed formal analysis, validation, and roles/writing—original draft. RS contributed to visualization, investigation, data curation, resources, and project administration. SS contributed to conceptualization, methodology, investigation, writing—review and editing. AS contributed to resources, funding acquisition, and project administration.

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Correspondence to S. Sivasankaran.

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Kaviyarasan, K., Soundararajan, R., Sivasankaran, S. et al. Influence of medium- and high-entropy alloy fillers on microstructures and corrosion behaviour of AA5083 plates joined by GTAW process. J Mater Sci 59, 7998–8021 (2024). https://doi.org/10.1007/s10853-024-09654-w

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  • DOI: https://doi.org/10.1007/s10853-024-09654-w

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