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Abstract. In the present investigation, the corrosive behaviour of Al 6061–TiN particulate composites prepared by
liquid metallurgy has been studied in chloride medium using electroanalytical techniques such as Tafel, cyclic polari-
zation and electrochemical impedance spectroscopy (EIS). Surface morphology of the sample electrodes was
examined using scanning electron micrography and energy dispersive X-ray methods. X-ray diffraction tech-
nique was used to confirm inclusion of TiN particulates in the matrix alloy and identify the alloying elements
and intermetallic compounds in the Al 6061 composites. Polarization studies indicate an increase in the co-
rrosion resistance in composites compared to the matrix alloy. EIS study reveals that the polarization resistance (Rp )
increases with increase in TiN content in composites, thus confirming improved corrosion resistance in composites.
The observed decrease in corrosion rate in the case of composites is due to decoupling between TiN particles and Al
6061 alloy. It is understood that after the initiation of corrosion, interfacial corrosion products may have decoupled
the conducting ceramic TiN from Al 6061 matrix alloy thus eliminating the galvanic effect between them.
1057
1058 H C Ananda Murthy, V Bheema Raju and C Shivakumara
the corrosive behaviour is equally important as studies on cut into rectangular specimens of 2 cm length, 1 cm width
fabrication and mechanical behaviour of Al MMCs. and 1 mm thickness and prepared as described above.
The present investigation involves the study of corrosive
behaviour of unreinforced Al-6061 matrix and its TiN parti-
culate composites in NaCl medium. Titanium nitride is a
hard, dense and refractory material with low electrical resisti- 3. Results and discussion
vity (∼10−7 ohm cm) and is isomorphous with TiC. TiN is
a good reinforcement for aluminium matrix, as it is known 3.1 Polarization measurements
to enhance corrosion resistance of the matrix. The main
Titanium nitride is a hard, dense and refractory material with
objective of the present study is to establish the role and
low electrical resistivity (∼10−7 ohm cm) and is isomorphous
effectiveness of TiN on the corrosive behaviour of Al 6061
with TiC. Also, TiN particles have poor wettability with
composites.
liquid aluminium. The open circuit potentials (OCP) were
recorded for Al6061 matrix alloy and its TiN composites
2. Experimental: Material selection (2, 4 and 6 wt%) in three different concentrations of neu-
tral NaCl media, viz. 0·1 N, 0·5 N and 1·0 N solutions. The
2.1 Aluminium alloy 6061 matrix plots for the matrix alloy and the composites in decinormal
NaCl medium is shown in figure 1 and the evaluated open
Aluminium alloy 6061 had the composition: Si – 0·6%, circuit potentials are given in table 1. It is observed that
Fe – 0·1%, Cu – 0·3%, Mn – 0·02%, Mg – 0·8%, Zn, Cr, the OCP values increase in positive direction with increase
Ti – 0·01% each and remaining Al. in TiN content, from −0·8062 V for Al 6061 matrix to
−0·7487 V for reinforced composites (6 wt% TiN) in 0·1 N
NaCl medium. Similar increase in OCP values in the positive
2.2 Reinforcement
direction with increase in TiN content is observed in 1 N NaCl
TiC of A.R. grade was obtained from Sigma Aldrich and used medium, from −0·8987 V for Al 6061 matrix to −0·7761 V
as reinforcement in the form of particulates. for reinforced composites (TiN – 6 wt%).
OCP values shift considerably towards negative direction
for Al 6061 matrix alloy and its TiN composites, as shown
2.3 Composite preparation in figures 2 and 3. The increase in OCP value in the cathodic
direction is about 90 mV as the concentration of NaCl is
The liquid metallurgy route using vortex technique was
increased by one order of magnitude, for the matrix alloy
employed to prepare the composites. Addition of reinforce-
as well as the composites. However, this increase in OCP
ment material TiO2 into the molten Al-6061 alloy melt was
value of 90 mV for TiN reinforcement is lower when com-
carried out by creating a vortex in the melt using a mechani-
pared to the corresponding increase of 140 mV for Al–TiO2
cal stainless steel stirrer coated with alumina (to prevent
composites.
migration of ferrous ions from the stirrer material to the
Typical polarization curves for Al 6061 matrix alloy
alloy). The stirrer was rotated at a speed of 450 rpm in order
and composites containing 2, 4 and 6% by weight of
to create the necessary vortex. TiO2 particles were pre-heated
TiN particulates in different concentrations of NaCl are
to 400 ◦ C and added into the vortex of liquid melt at a rate
shown in figures 4–6. The evaluated electrochemical corro-
of 120 g/min. TiO2 particulates were in the size range of
sion parameters for the matrix alloy and the composites are
50–80 μm. The weight percentage of TiO2 used was 2–6
in steps of 2%. The composite melt was thoroughly stirred
and subsequently degasifiers were added. Castings were pro-
duced in permanent moulds in the form of cylindrical rods
(diameter, 30 mm and length, 150 mm).
Table 1. Open circuit potentials of Al 6061 matrix alloy and its TiN compo-
sites in various concentrations of NaCl media.
Figure 4. Tafel polarization plots for Al 6061 matrix alloy and its
Figure 2. Open circuit potentials for Al 6061 matrix alloy and its TiN (2, 4 and 6 wt%) composites in 0·1 NaCl medium.
TiN (2, 4 and 6 wt%) composites in 0·5 NaCl medium.
Figure 5. Tafel polarization plots for Al 6061 matrix alloy and its
TiN (2, 4 and 6 wt%) composites in 0·5 NaCl medium.
Figure 3. Open circuit potentials for Al 6061 matrix alloy and its
TiN (2, 4 and 6 wt%) composites in 1·0 NaCl medium.
were found to be similar in overall shape. Cyclic polariza-
tion measurements show that the pitting potential increases
given in tables 2 and 3. The corrosion parameters, corro- towards positive direction with increase in TiN content con-
sion current density (Icorr ) and corrosion rate were obtained firming the results from other measurements that composites
from the Tafel polarization measurements. It can be observed of TiN are more corrosion resistant than the matrix alloy.
from the Tafel plots and the tables that corrosion current va- Open circuit potential measurements revealed that the
lues and corrosion rates decrease with increase in TiN con- corrosion susceptibility of the matrix alloy decreases with
tent in the composites, in each of the NaCl concentrations. increase in TiN content in the composites. TiN reinforcement
Cyclic polarization curves for Al 6061 matrix alloy and com- particles thus impart good corrosion resistance to the Al–TiN
posites containing 2, 4 and 6% by weight of TiN particulates, composites with an increase in the concentration of the chlo-
in 0·5 N NaCl solution are shown in figure 7. Cyclic polari- ride medium from 0·1 N to 0·5 N to 1·0 N NaCl. Our results
zation curves of the reinforced and unreinforced Al alloys suggest the presence of lower percentage of TiN particulates
1060 H C Ananda Murthy, V Bheema Raju and C Shivakumara
Table 2. Corrosion current densities (Icorr ) of Al 6061 matrix alloy and its
TiN composites in various concentrations of NaCl media.
Table 3. Corrosion rates of Al 6061 matrix alloy and its TiN composites in
various NaCl media.
in composites which could be attributed to its poor wetta- increase in Cl− ion concentrations yields more cathodic OCP
bility as compared to TiO2 particles (Rhee 1970). The con- values confirming enhanced adsorptivity of Cl− ions in both
ducting TiN particulate possibly forms microgalvanic couple matrix alloy and its TiN composites. This corroborates the
with Al 6061 matrix alloy and causes pitting corrosion. The report by earlier researchers suggesting greater degree of
observed decrease in corrosion rate in the case of compo- penetration ability of chloride ions into the passive hydrated
sites is due to decoupling between TiN particles and Al 6061. oxides of aluminium as well as reduction in the kinetics of
It seems that after the initiation of corrosion, interfacial co- oxide film repair.
rrosion products may have decoupled the conducting ceramic Tafel polarization results show that TiN-reinforced com-
TiN from Al 6061 matrix alloy, thus eliminating the galvanic posites have lower corrosion rate as compared to matrix
effect between them (Srinivasan 2005). alloy. Observations also show that both the Icorr values and
Increase in the corrosion susceptibility of both Al 6061 corrosion rate decrease with increase in content of TiN and
matrix alloy and composites at higher concentrations of increase with an increase in concentration of NaCl medium.
aggressive chloride ions is probably due to the breakdown of This observation contradicts the composite theory of corro-
stable oxide film on Al 6061 matrix as a result of increased sion according to which reinforcement particles cause cracks
adsorption of chloride ions. This indicates the lowest co- and discontinuity on the surface of metal/alloy (Trowsdale
rrosion tendency for the TiN (6 wt%)-reinforced composites et al 1996). It is observed that the interface between Al
as compared to matrix alloy. The results show that the 6061 matrix and TiN reinforcement is stronger as reported
Corrosive behaviour of aluminium 6061 composites 1061
(Sharma 2001) in the study of corrosive behaviour of Al of immersion (Alaneme 2011). It has been reported that in
6061/albite composite. In the unreinforced Al alloy, the po- the case of TiN-reinforced Al MMCs fabricated by pow-
ssible cathodic sites could be eutectic silicon and/or inter- der metallurgical route (Ray et al 2002) that the presence of
metallic precipitates; however, in the composites, cathodic TiN-particles at grain boundaries played a significant role in
sites may be reinforcements, second-phase precipitates or its densification and improved mechanical as well as wear
interfacial reaction products (Nunes and Ramanathan 1995). resistance properties. The improved corrosion resistance in
The presence of a more conductive phase at the inter- TiN-reinforced Al 6061 composites compared to matrix alloy
face provides an easier path for the electron exchange nece- can be attributed to good interface bonding between the
ssary for oxygen reduction and drives the anodic reaction at a ceramic TiN and Al matrix alloy (Das 2004). TiN parti-
higher rate in MMCs than aluminium alloy. Improved corro- cle reinforced composites exhibit lesser surface irregularities
sion resistance has been reported (Wlodarczyk-Fligier et al which is due to refined microstructure as observed during the
2010) in Al composites reinforced up to 5% Ti(C, N) par- study of electrochemical behaviour of haematite particulates
ticulates when compared with the matrix alloy in 3% NaCl reinforced Al alloys (Jagadeesh et al 2005).
medium. This corroborates the prediction that presence of A probable explanation for the observed trend in pitting
a small amount of TiN reinforcement in composites fails to corrosion could be that the pitting is initiated at random
rupture the oxide layer of Al. It is believed that the nature sites of imperfections on the protective oxide layer of the
of the passive film formed on the TiN composites is su- matrix alloy, while in the composites, pits around the rein-
fficiently stable to reduce the corrosion rate after few min forcement particles coalesce to form a crevice. The active
nature of the crevices would cathodically protect the remain-
der of the matrix and restrict pit formation and propaga-
tion (Garrard 1994). It is found that E RP values increase in
the noble direction with increasing TiN content in compo-
sites. This points to the fact that pit propagation in the com-
posites is retarded more significantly than in the Al 6061
matrix alloy. The higher repassivation potential exhibited by
the TiN-reinforced composites is attributable to the reduc-
tion in the pit dissolution kinetics by the oxides of metals.
However, the repassivation potentials are more negative to
the pitting potentials for each of the composites as well as
the Al 6061 matrix alloy indicating a tendency to undergo
pitting. E 1 is the direct measure of pitting susceptibility
and is used to assess the repassivation behaviour of pro-
pagating pits, the ease with which local active sites can be
eliminated.
Figure 8. SEM micrograph of Al 6061 matrix alloy.
Figure 15. EDX spectrum of interface between TiN and Al 6061 matrix.
A rapid dissolution of aluminium within the pit tends to surface. The back-scattered SEM image of TiN (6 wt%)-
produce an excess of positive charge in this area. The migra- reinforced Al 6061 sample is shown in figure 14. The pre-
tion of chloride ions towards the pit increases the concen- sence of less intense peaks for the elements Ti and N in the
tration of AlCl3 in the pit. Since the solubility of oxygen is EDX spectrum of TiN (6 wt%)-reinforced Al 6061 compo-
virtually zero in concentrated solution, no reduction of oxy- site confirms the incorporation of TiN particles into Al matrix,
gen occurs within the pit. Cathodic oxygen reduction on sur- but only to a small extent as it exhibits low wettability.
faces adjacent to pits tends to suppress the corrosion thereby Even though galvanic coupling is assumed to be esta-
protecting the matrix metal adjacent to the pit (Ramachandra blished between conductive TiN and Al matrix alloy, the
and Radhakrishna 2006). extent of corrosion is insignificant (Adler et al 2008) even
at 6 wt% of TiN particles in composites. It is observed that
3.3 Energy dispersive X-ray analysis the matrix alloy and composites contain Al–Fe–Si-rich and
Mg2 Si intermetallic phases.
Energy dispersive X-ray (EDX) analysis spectra shows the
The elements in these intermetallic phases undergo oxi-
presence of various elements in the TiN-reinforced Al 6061
dation to yield their respective oxides such as SiO2 , FeO
and MgO, which reduce the corrosion rate in composites by
decreasing the microgalvanic coupling between conducting
intermetallic phases and matrix alloy. The presence of SiO2 ,
FeO and MgO at the interface between TiN and Al 6061 is
confirmed by EDX spectrum which showed intense peaks for
Si, Fe, Mg and O as shown in figure 15. Corrosion resistance
is more pronounced in TiN-reinforced composites as they
contain higher amount of intermetallic phases due to the po-
ssible increased reactivity between the reinforcement particle
and other alloying elements.
Figure 17. XRD pattern of TiN phase in Al 6061–TiN (6 wt%) X-ray diffraction (XRD) pattern of the composite (6 wt%
composite. TiO2 -reinforced) and that of TiN particulates is given in
figures 16 and 17. XRD spectra of the composite clearly shows
major 2θ peaks of TiN (36·87◦ , 42·78◦ and 61·98◦ ) in the TiN
(6%)-reinforced Al 6061 composite indicating the incorpora-
tion of reinforcement particulates in the matrix alloy.
Table 4. Electrochemical parameters for Al 6061 matrix alloy and its TiN
composites obtained from EIS studies.
Based on the analysis of the impedance spectra, an equivalent Impedance spectroscopic studies show decreasing trend
circuit model R[QR[LR]] was proposed for both the matrix of polarization resistance, RP , on increase of TiN
alloy (figure 19) and composites (figure 20), simulating their reinforcement.
electrochemical behaviour. The measured value of polarization resistance, Rp ,
It can be found that the impedance spectra of all the sam- increases while the CPE value decreases with increase in
ples are dominated by capacitance of the oxide film, but the TiN content. This shows that the corrosion rate decreases
diameters of the capacitance arcs increase with increase in with increase in the content of TiN reinforcement. It is also
TiN content, which means that the resistance of the surface observed that the Rp value increases with increase in TiN
oxide film on the composites increases with increase in TiN content confirming improved corrosion resistance in com-
reinforcement. posites. These results complement polarization tests and are
This can be attributed to the fact that the hydroxide formed similar to the TiO2 composites system.
by the oxides of Si, Mg and Al plays an inhibitive role around
conducting TiN and intermetallic phases. The equivalent cir-
cuit consists of a constant phase element (CPE), Q, in para- 4. Conclusions
llel with the parallel resistors, Rt (charge transfer resistance)
and RL (inductance resistance) and the latter is in series with The corrosion behaviour of unreinforced Al 6061 matrix
the inductor L. In this case, the polarization resistance can be alloy and its composites reinforced with TiN (2, 4 and
calculated using the formula as given below: 6 wt%) were studied in 0·1 N, 0·5 N and 1 N NaCl media.
Corrosion rates of the matrix alloy and the composites from
RL × Rt the polarization curves, show a decrease with increase in
Rp = .
RL + Rt the content of TiN reinforcement. Increased corrosion resis-
tance in composites is believed to be due to reinforcement
particulates modifying the microstructure of matrix and also
acting as physical barrier to the initiation and development
of pitting corrosion. Increase in the corrosion susceptibility
of both Al 6061 matrix alloy and the composites at higher
concentrations of aggressive chloride ions is probably due
to the breakdown of stable oxide film on Al 6061 matrix as
a result of increased adsorption of chloride ions. XRD and
EDX analysis of all the composites confirm positive inclu-
sion of the reinforcement particulates in the matrix alloy
and also the presence of intermetallic phases such as Al–
Fe–Si-rich and Mg2 Si formed at matrix-reinforcement inter-
face. SEM pictures reveal severe deterioration of the surface
of both matrix alloy and its composites of all the reinforce-
ments. The measured value of polarization resistance, Rp ,
increases while the CPE value decreases with increase in
Figure 19. Equivalent circuit model used to fit the experimental content of reinforcement in all the cases.
data of Al 6061 matrix alloy in 0·5 N NaCl medium.
Acknowledgements
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