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Effect of Zn coating on microstructure and corrosion behavior of dissimilar joints between aluminum alloy and steel by refilled friction stir spot welding

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Abstract

Refilled friction stir spot welding of aluminum alloy to galvanized and uncoated steel was conducted, and the microstructure and the corrosion behavior of joints were investigated. Al5FeSi phases distributed in TMAZ and broke during tool stirring in NZ, which induced the pitting corrosion in 3.5 wt% NaCl solution. The maximum corrosion depth of ST-Al/ST06 Z joint was up to 21.3 μm at the mixed layer, which was 2.8 μm deeper than that of ST-Al/ST16 joint at the interface between aluminum alloy and steel. Zn and Mg segregated at the grain boundaries of the mixed layer, resulting in serious intergranular corrosion. The corrosion current density of ST-Al/ST06 Z joint ((8.1 ± 0.2) × 10–6 A/cm−2) is higher than that of ST-Al/ST16 joint ((7.9 ± 0.4) × 10–6 A/cm−2) after immersion for 1 h in 3.5 wt% NaCl solution. The corrosion current densities of samples were minimum for 6 h immersion time, which was related to the passivation films and corrosion products formed on the joint surface.

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Acknowledgements

This work was supported by the National Natural Science Foundation of China (No. 51674060) and the Collaborative Innovation Center of Major Machine Manufacturing in Liaoning, China.

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Authors and Affiliations

  1. School of Materials Science and Engineering, Dalian University of Technology, Dalian, 116024, People’s Republic of China

    Yueting Ma, Honggang Dong, Yaqiang Wang, Yueqing Xia, Peng Li, Xiaohu Hao, Jiang Yang, Baizheng Guo & Mingkai Lei

  2. Aerospace Engineering Equipment (Suzhou) Co. Ltd., Suzhou, 215104, People’s Republic of China

    Guoshun Yang & Hua Ji

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  1. Yueting Ma
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Ma, Y., Dong, H., Wang, Y. et al. Effect of Zn coating on microstructure and corrosion behavior of dissimilar joints between aluminum alloy and steel by refilled friction stir spot welding. J Appl Electrochem 52, 85–102 (2022). https://doi.org/10.1007/s10800-021-01610-9

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