Laser Surface Alloying of Aluminum for Improving Acid Corrosion Resistance

  • Woldetinsay Gutu Jiru
  • Mamilla Ravi Sankar
  • Uday Shanker Dixit
Original Contribution


In the present study, laser surface alloying of aluminum with magnesium, manganese, titanium and zinc, respectively, was carried out to improve acid corrosion resistance. Laser surface alloying was conducted using 1600 and 1800 W power source using CO2 laser. Acid corrosion resistance was tested by dipping the samples in a solution of 2.5% H2SO4 for 200 h. The weight loss due to acid corrosion was reduced by 55% for AlTi, 41% for AlMg alloy, 36% for AlZn and 22% for AlMn alloy. Laser surface alloyed samples offered greater corrosion resistance than the aluminum substrate. It was observed that localized pitting corrosion was the major factor to damage the surface when exposed for a long time. The hardness after laser surface alloying was increased by a factor of 8.7, 3.4, 2.7 and 2 by alloying with Mn, Mg, Ti and Zn, respectively. After corrosion test, hardness was reduced by 51% for AlTi sample, 40% for AlMg sample, 41.4% for AlMn sample and 33% for AlZn sample.


Pitting corrosion Laser surface alloying Aluminum Magnesium Manganese Titanium Zinc 



This paper is a revised and enhanced version of the paper entitled ‘Improving acid corrosion resistance of pure aluminium by laser surface alloying with Mg and Mn’ presented at the Fourth International Conference on Production and Industrial Engineering (CPIE2016) held at Dr. B.R. Ambedkar National Institute of Technology, Jalandhar during 19–21, December 2016. Authors thank the organizers of the Conference. The authors are also grateful for the financial support provided by Indian Institute of Technology Guwahati (SG/ME/P/MRS/01), Board of Research in Nuclear Sciences (ME/P/MRS/02), Department of Electronics & Information Technology (Grant No. 5(9)/2012-NANO), and Department of Science and Technology for ‘Technology Systems Development Programme (DST/TSG/AMT/2015/619)’.


  1. 1.
    E. Bardal, Corrosion and Protection (Springer, London, 2007)Google Scholar
  2. 2.
    H. Kaesche, Corrosion of Metals: Physicochemical Principles and Current Problems (Springer, Berlin, 2012)Google Scholar
  3. 3.
    R. Rosliza, W.W. Nik, H.B. Senin, The effect of inhibitor on the corrosion of aluminum alloys in acidic solutions. Mater. Chem. Phys. 107(2), 281–288 (2008)CrossRefGoogle Scholar
  4. 4.
    M.A. Fouad, T.M. Zewail, N.A. Amine, Y.A. El-Tawail, Comparison between corrosion behavior of copper and stainless steel 90° elbow and failure investigation of 90° copper elbow. J. Inst. Eng. Ser. C 98(2), 141–145 (2017)CrossRefGoogle Scholar
  5. 5.
    E.F. El-Sherbini, S.M. Abd-El-Wahab, M.A. Deyab, Studies on corrosion inhibition of aluminum in 1.0 M HCl and 1.0 MH2SO4 solutions by ethoxylated fatty acids. Mater. Chem. Phys. 82(3), 631–637 (2003)CrossRefGoogle Scholar
  6. 6.
    V. Branzoi, F. Golgovici, F. Branzoi, Aluminium corrosion in hydrochloric acid solutions and the effect of some organic inhibitors. Mater. Chem. Phys. 78(1), 122–123 (2002)CrossRefGoogle Scholar
  7. 7.
    A.P.I. Popoola, S.L. Pityana, O.M. Popoola, Laser deposition of (Cu + Mo) alloying reinforcements on AA1200 substrate for corrosion improvement. Int. J. Electrochem. Sci. 6, 5038–5051 (2011)Google Scholar
  8. 8.
    C.T. Kwok, P.K. Wong, Laser surface alloying of various engineering alloys for sliding wear and corrosion resistance. J. Laser Micro/Nanoeng. 5(1), 90–96 (2010)CrossRefGoogle Scholar
  9. 9.
    W.G. Jiru, M.R. Sankar, U.S. Dixit, Laser surface alloying of copper, manganese, and magnesium with pure aluminum substrate. J. Mater. Eng. Perform. 25(3), 1172–1181 (2016)CrossRefGoogle Scholar
  10. 10.
    C.V. Moorthy, V. Srinivas, Corrosion and heat transfer characteristics of water dispersed with carboxylate additives and multi walled carbon nano tubes. J. Inst. Eng. Ser. C 97(4), 569–577 (2016)CrossRefGoogle Scholar
  11. 11.
    B.R. Hinton, Corrosion Prevention and Control, Handbook on the Physics and Chemistry of Rare Earths (Elsevier, Amsterdam, 1995)Google Scholar
  12. 12.
    H. Kamoutsi, G.N. Haidemenopoulos, V. Bontozoglou, S. Pantelakis, Corrosion-induced hydrogen embrittlement in aluminum alloy 2024. Corros. Sci. 48(5), 1209–1224 (2006)CrossRefGoogle Scholar
  13. 13.
    Z. Szklarska-Smialowska, Pitting corrosion of aluminum. Corros. Sci. 41(9), 1743–1767 (1999)CrossRefGoogle Scholar
  14. 14.
    D.J. Majumdar, A. Weisheit, B.L. Mordike, I. Manna, Laser surface alloying of Ti with Si, Al and Si + Al for an improved oxidation resistance. Mater. Sci. Eng. A 266(1), 123–134 (1999)CrossRefGoogle Scholar
  15. 15.
    J.H. Abboud, D.R.F. West, Laser surface alloying of titanium with aluminium. J. Mater. Sci. Lett. 9(3), 308–310 (1990)CrossRefGoogle Scholar
  16. 16.
    A.E. Ares, L.M. Gassa, Corrosion susceptibility of Zn–Al alloys with different grains and dendritic microstructures in NaCl solutions. Corros. Scie. 59, 290–306 (2012)CrossRefGoogle Scholar
  17. 17.
    L. Yang, Y. Zhang, X. Zeng, Z. Song, Corrosion behaviour of superplastic Zn–Al alloys in simulated acid rain. Corros. Sci. 59, 229–237 (2012)CrossRefGoogle Scholar
  18. 18.
    W.G. Jiru, M.R. Sankar, U.S. Dixit, Improving acid corrosion resistance of pure aluminium by laser surface alloying with Mg and Mn, Proceedings of IVth International Conference on Production & Industrial Engineering (CPIE 2016) held at Dr. B.R. Ambedkar National Institute of Technology, Jalandhar during 19–21 December 2016Google Scholar
  19. 19.
    W.G. Jiru, M.R. Sankar, U.S. Dixit, Laser surface alloying aluminum with copper using CO2 laser, Lasers Based Manufacturing, ed. by S.N. Joshi, U.S. Dixit (Springer, New Delhi, 2015), pp. 107–116Google Scholar
  20. 20.
    L.P. Arellanes, X.O. Olivares, L.D. Guzmán, N.V. Likhanova, A.M.A. Domínguez, I.V. Lijanova, E.E. Arce, The inhibition of aluminum corrosion in sulfuric acid by poly (1-vinyl-3-alkyl-imidazolium hexafluorophosphate). Materials 7(8), 5711–5734 (2014)CrossRefGoogle Scholar
  21. 21.
    A.I. Zhurin, A.I. Kosmynin, O.B. Vlasenko, Corrosion of aluminum cathodes during the electrodeposition of zinc. Izv. Vyssh. Ucheb. Zaved. Tsvet. Metall. 5, 71–75 (1973)Google Scholar
  22. 22.
    A.S.M. Handbook, Welding, Brazing and Soldering (ASM International, Materials Park, 1993)Google Scholar
  23. 23.
    C. Vargel, Corrosion of Aluminium (Elsevier, London, 2004)Google Scholar
  24. 24.
    Y. Huang, L. Gao, Z. Yi, K. Tai, P. Kalita, P. Prapainainar, A. Garg, An application of evolutionary system identification algorithm in modelling of energy production system. Measurement 114, 122–131 (2018)CrossRefGoogle Scholar
  25. 25.
    A. Garg, V. Vijayaraghavan, J. Zhang, J.S.L. Lam, Robust model design for evaluation of power characteristics of the cleaner energy system. Renew. Energy 112, 302–313 (2017)CrossRefGoogle Scholar
  26. 26.
    A. Garg, J. Li, J. Hou, C. Berretta, A. Garg, Anew computational approach for estimation of wilting point for green infrastructure. Measurement 111, 351–358 (2017)CrossRefGoogle Scholar
  27. 27.
    A. Garg et al., Design of robust battery capacity model for electric vehicle by incorporation of uncertainties. Int. J. Energy Res. 41(10), 1436–1451 (2017)CrossRefGoogle Scholar

Copyright information

© The Institution of Engineers (India) 2018

Authors and Affiliations

  • Woldetinsay Gutu Jiru
    • 1
  • Mamilla Ravi Sankar
    • 1
  • Uday Shanker Dixit
    • 1
  1. 1.Department of Mechanical EngineeringIndian Institute of Technology GuwahatiGuwahatiIndia

Personalised recommendations