A Guide for Aluminum Alloy Corrosion and Prevention

A Guide for Aluminum Alloy Corrosion and Prevention

Corrosion is a significant concern for industries that utilize aluminum alloys due to their widespread applications.

During the corrosion process, metals undergo an electrical chemical reaction where they change from an atomic state to an ionic state. Aluminum has a highly negative potential, indicating that it is highly active and susceptible to corrosive reactions. However, in the presence of oxygen and clean water, aluminum alloys exhibit excellent corrosion resistance due to the formation of a protective oxide film on the surface. This oxide film blocks the contact of the substrate with the corrosive environment, thereby improving corrosion resistance.Under normal conditions, the thickness of the oxide film formed in air is about 50Å (5 nm) and increases with temperature. While aluminum alloys develop a protective oxide film on the surface, it is important to note that they are stable within a pH range of 4 to 8.5. However, they are easily dissolved in strong acids or strong alkaline environments. Once the protective film is dissolved, exposed aluminum surfaces are susceptible to rapid corrosion.


Corrosion of Aluminum Alloy at Different pH Values

1.pH 4 to 8.5:
In the pH range of 4 to 8.5, aluminum alloy exhibits relatively good corrosion resistance. The passive oxide film formed on the surface acts as a protective barrier against corrosion. This oxide film is stable and self-healing, which helps prevent the penetration of corrosive agents and protects the underlying metal. Therefore, corrosion rates in this pH range are generally low.

2.pH > 8.5:
At pH values higher than 8.5 (alkaline conditions), aluminum alloy can experience increased susceptibility to localized corrosion, especially if the alloy contains high levels of alloying elements that are less resistant to corrosion, such as copper. The alkaline environment promotes the breakdown of the protective oxide film, leading to localized corrosion phenomena like pitting corrosion or intergranular corrosion. The alkaline pH can also promote the formation of more porous oxide films, reducing corrosion resistance.

3.pH < 4:
When the pH value drops below 4 (acidic conditions), the protective oxide film on the aluminum alloy surface can be destabilized or dissolved. The acidic environment can accelerate the dissolution rate of aluminum and the breakdown of the oxide film. This results in a decrease in the corrosion resistance of the alloy, making it more susceptible to corrosive attack.

A protective oxide film is formed on the surface of the aluminum alloy; however, this oxide film is only stable within a pH range of approximately 4-8.5. Due to the limited surface area of the oxide film and its potential nonuniformity, localized corrosion can occur in the aluminum alloy, even in the environment with a pH value between 4 and 8.5, due to the breakdown of the localized oxide film.

Table 1 PH Diagram

Localized corrosion of aluminum alloy

It is important to note that the specific corrosion behavior of aluminum alloy will also depend on factors other than pH, such as the alloy composition, presence of impurities, temperature, and exposure to specific corrosive agents. To assess the corrosion performance accurately, it is recommended to consider these factors in conjunction with pH values.


Aluminum alloy corrosion is primarily attributed to the electrical chemical reactions between the alloy and the surrounding environment. One common type of corrosion is uniform corrosion, which occurs uniformly across the surface. This is typically caused by exposure to corrosive agents like moisture, acid rain, and industrial pollutants. Localized corrosion is another form that arises from the presence of small defects or the combination of different materials. This phenomenon includes pitting corrosion, crevice corrosion, layer corrosion, deposition corrosion, stray current corrosion, stress corrosion cracking (SCC).


Table 2: SCC of Aluminum Alloys


How to prevent corrosion ?

To effectively combat corrosion in aluminum alloys, one notable approach is the application of protective coatings. These coatings act as a barrier between the alloy and the corrosive environment, significantly reducing the direct contact and slowing down the corrosion rate. Commonly used coatings include organic coatings, anodizing, and conversion coatings. The choice of coating depends on factors such as the alloy composition, the severity of exposure, and the intended application.


Another preventive measure involves alloy composition optimization. By adjusting the composition, engineers can enhance the corrosion resistance of aluminum alloys. Adding elements like zinc, copper, and magnesium can form protective oxide layers and improve overall stability. However, it is crucial to strike a balance as excessive additions may decrease other desirable properties of the alloy.


In addition to protective coatings and composition optimization, proper maintenance and regular inspections are paramount in preventing corrosion. Regular cleaning and removal of accumulated contaminants can help minimize the corrosion risk. Physical protection from corrosive environments, such as utilizing protective barriers and controlled humidity levels, can also contribute to the prevention efforts.


As industries continue to advance, new challenges arise, requiring innovative solutions to combat corrosion effectively. Collaborative efforts between researchers, industry professionals, and policymakers are crucial to developing more sustainable and corrosion-resistant aluminum alloys.


In conclusion, corrosion poses a significant threat to aluminum alloy structures. Understanding the causes of corrosion, implementing preventive measures like protective coatings and alloy composition optimization, and maintaining regular inspections and maintenance are key to combating this issue. With further research and collaboration, we can ensure the longevity and reliability of aluminum alloy structures in various applications.


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