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Abstract
This paper describes a study of the corrosion characteristics of LM13 Al alloy-based
composites reinforced with various amounts of garnet particulates. The weight loss method
was used and the corrodent was 1 M HCl solution at room temperature. The durations of the
tests ranged from 24 to 96 h. Corrosion tests were performed on the unreinforced matrix alloy
as well as on the various composites in both heat-treated and as-cast conditions. In each test,
the corrosion rates of the unreinforced matrix alloy and the composites were found to decrease
with duration of exposure to the corrodent. Solution heat treatment at 525C followed by
articial aging at 175C was found to improve the corrosion resistance of every specimen
tested. Corrosion resistance was also found to improve with increase in garnet content. An
attempt is made in the paper to explain these phenomena. 2002 Elsevier Science Ltd. All
rights reserved.
Keywords: LM13; Aluminium alloy; Garnet; Corrosion; Metal matrix composite
1. Introduction
Metal matrix composites (MMCs) oer designers many benets as they are
particularly suited for applications requiring good strength at high temperature,
good structural rigidity, dimensional stability, and light weight [15]. The trend is
0010-938X/02/$ - see front matter 2002 Elsevier Science Ltd. All rights reserved.
PII: S 0 0 1 0 - 9 3 8 X ( 0 1 ) 0 0 0 9 9 - 3
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towards safe usage of the MMC parts in the automobile engine, which work particularly at high temperature and pressure environments [6,7]. Particulate reinforced
MMCs have been the most popular MMCs over the last two decades. Of these,
ceramic reinforced Al-based MMCs are the most common. Although the incorporation of a second phase into a matrix material can enhance the physical and mechanical properties of the latter, it could also signicantly change the corrosion
behaviour.
Particulate reinforced Al-based MMCs nd potential applications in several
thermal environments, especially in automobile engine parts such as drive shafts,
cylinders, pistons, and brake rotors. Al-based MMCs which are used in automobile
engine parts normally encounter acidic environments containing chloride, sulphiate
and nitrate radicals, in addition to exhaust gases like CO2 , CO and NOx . MMCs
used at high temperatures should have good mechanical properties and resistance to
chemical degradation in air and acidic environments [8]. For high-temperature applications, it is essential to have a thorough understanding of the corrosion behaviour of the aluminium composites. Published data [911] indicate that the addition of
SiC particles do not appear to improve corrosion resistance on some aluminium
alloys because pits were found to be more numerous on the composites than on the
unreinforced alloys although they were comparatively smaller and shallower than
those on the unreinforced alloy. Gonzalez et al. [12] reported that the presence of SiC
particles does not give rise to signicant galvanic corrosion and no active phases are
formed at the matrix/particle interface. Nevertheless, the present study is aimed at
characterising the corrosion behaviour of LM13 Al alloy and the eect of reinforcing
it with garnet particles in both the as-cast and the heat-treated conditions.
2. Experimental procedure
2.1. Constituent materials of composites
The matrix alloy used for the composites is LM13 Al alloy, a material suitable for
mass production of lightweight castings which can either be sand-cast or die-cast.
The chemical composition of the LM13 alloy is given in Table 1.
Garnet, the reinforcement material, is abundantly available in the earth and has
a Mohrs hardness of 6.57.0 which is nearly equal to that of SiC. It is composed
of alumino-silicates of calcium, having the chemical formula Ca2 Al2 (SiO4 )3 and is
chemically inert at elevated temperatures. It does not have a sharp melting point
although it softens at temperatures of 11401280C.
Table 1
Chemical composition of matrix LM13 alloy by weight percentage
Mg
Si
Fe
Cu
Ti
Pb
Zn
Mn
Sn
Ni
Al
0.81.5
1012
1.0
0.71.5
0.2
0.1
0.5
0.5
0.1
1.5
balance
919
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Fig. 1. (a) Photomicrograph showing dendritic structure of unreinforced LM13 alloy. (b) Microstructure
of LM13-based MMC reinforced with 6% garnet.
921
Table 2
Corrosion rate of as-cast and heat-treated LM13 alloy and MMCs for dierent durations of exposure to
HCl solution
Aging time (h)
After 48 h
exposure
After 72 h
exposure
After 96 h
exposure
0
2
4
6
10.93
10.80
9.15
8.66
5.64
5.52
5.07
4.68
4.12
4.02
3.52
3.55
3.21
3.11
3.06
3.00
0
2
4
6
7.97
7.47
7.18
6.60
4.47
4.24
4.20
4.47
3.25
3.16
2.82
2.79
2.97
2.83
2.41
2.31
0
2
4
6
7.72
7.38
6.16
6.40
3.65
3.63
3.60
3.58
2.88
2.83
2.72
2.91
2.30
2.12
2.11
2.10
12
0
2
4
6
7.68
7.09
5.99
5.79
3.98
3.10
3.37
3.35
2.83
2.56
2.67
2.69
2.22
2.02
2.01
1.95
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Fig. 2. Graphs of corrosion rates of LM13 alloy and MMCs vs. exposure time in 1 M HCl solution for
various durations of aging.
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Fig. 3. Eect of articial aging on corrosion rate of LM13 alloy and MMCs after 24 h of exposure in 1 M
HCl solution.
the corrosion rate to drop by about one-third. One possibility is that the articial
aging has enhanced the protective layer of aluminium oxide described above, conferring greater corrosion resistance to the corrodent which is seen in all the specimens, unreinforced as well as reinforced, no matter what the garnet content is.
As aging duration is increased beyond 4 h, the benecial eect on corrosion resistance apparently levels o, probably due to the protective layer of aluminium oxide
reaching a steady state with time during aging, which was done after the specimen
had been machined.
3.4. Eect of garnet content
From Table 2 and Fig. 2, it is apparent that for materials in both the as-cast and
aged conditions, there is a trend of decreasing corrosion rate with increase in garnet
content, especially for shorter exposure times. For long exposure times, however, this
eect is less pronounced.
The corrosion rate of the unreinforced matrix alloy is higher than those of the
composites because in the former, there is no reinforcement phase and the matrix
alloy does not have much corrosion resistance to the acid medium. Garnet, being a
ceramic, remains inert and is itself unaected by the acidic medium during the tests.
The inert garnet particulates are also not expected to aect electrochemically the
corrosion mechanism of the composite. Nevertheless, the results show an improvement in corrosion resistance as the garnet content is increased in the composite,
indicating that the garnet particulates do inuence the corrosion characteristics of
the composites albeit not electrochemically. Sharma et al. [16] obtained similar
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results in short glass ber reinforced ZA-27 aluminium alloy composites, observing
that the corrosion resistance increases with increase in reinforcement content.
Wu Jianxin et al. [17] in their work on corrosion of SiC particulate reinforced Albased MMCs state that this corrosion behaviour is not aected to a signicant extent
by the presence of the SiC, although these particulates denitely play a subsidiary
role as physical barriers to MMC corrosion. According to them, particulates act as
inert physical barriers to the initiation and development of pitting corrosion, modifying the microstructure of the matrix material and hence improving the corrosion
resistance of the MMC.
Another reason for the decrease in the corrosion rate could be the formation of a
magnesium inter-metallic layer adjacent to the particle during fabrication of the
specimen as discussed by Trzaskoma [9]. McIntyre et al. [18], in their research on
MMCs, showed that the magnesium inter-metallic compounds are more active than
the alloy matrix causing more pitting in the particle/matrix interfaces because of the
higher magnesium content in such regions. These electrochemically active crevices
act as sacricial anodes and protect the rest of the matrix, restricting pit formation
and propagation to only these crevices [19]. Further evidence of the formation of a
magnesium layer can be found in another paper by Sharma [20].
4. Conclusions
In the present study of garnet particulate reinforced LM13 Al alloy MMCs,
corrosion resistances of the unreinforced matrix alloy and the composites were found
to improve with duration of exposure to the corrodent. Solution heat treatment at
525C followed by articial aging at 175C was found to improve the corrosion
resistance of every specimen tested. The improvement in corrosion resistance due to
these two factors is attributed to a protective layer formed on the surface of the
material. Corrosion resistance was also found to improve with increase in garnet
content, probably due to the garnet particles acting as physical barriers to the corrosion process.
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