Corrosion behavior of joints by electromagnetic pulse welding with aluminum to steel in neutral salt spray
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摘要: 为了获得铝钢电磁脉冲焊接接头中性盐雾介质的腐蚀过程及机理，对5%NaCl腐蚀后的焊接接头进行拉剪试验，并采用带能谱的扫描电子显微镜进行断口微观形貌分析. 结果表明，铝钢电磁脉冲焊接接头中性盐雾腐蚀3天后的抗剪强度由原态74 MPa降为33 MPa，为原态的44.6%，腐蚀周期7天时，焊缝完全失效；在焊缝外围，粒子流击碎铝板表面氧化物生成粒状腐蚀物NaAlO2，焊缝上FeAl3破碎，露出铝被快速腐蚀为Al(OH)3；在铝板表面撞击产生凹坑和嵌入钢板表面片状铝的位置最先被腐蚀，NaCl液体堆积并在表层金属下流动腐蚀，且沿着腐蚀坑互连方向扩展，再向焊缝存在FeAl3相的连接区延伸；当氧化膜或焊缝被NaCl介质腐蚀抬起且破碎后，向着铝基体深层腐蚀，形成多而深的沟壑或凹坑，这成为接头快速失效的主要腐蚀机理.Abstract: In order to obtain the corrosion process and mechanism of joints by electromagnetic pulse(EMP) welded with aluminum to steel in neutral salt spray medium of 5%NaCl, shear test was performed and the shear fracture morphologies were analyzed by scanning electron microscopy. The results showed that the shear strength of the welded joint decreased from 74 MPa to 33 MPa after 3 days in the neutral salt spray corrosion, which was 44.6% of the original shear strength, and the weld failed completely after 7 days in corrosion. At the periphery of the weld, particle flow impacted the oxides at the surface of the aluminum plate to form granular corrosion NaAlO2, and FeAl3 at the weld was broken, exposing the aluminum to be rapidly corroded into Al(OH)3. Where the impact pits at the surface of the aluminum plate and the embedded aluminum metal at the surface of the steel plate was the place first to be corroded, NaCl liquids accumulated and flowed under the metal surface for corrosion, and expanded along the direction of corrosion pits interconnection, and then extended to the joint zone where FeAl3 phase existed in the weld. When the oxide or the weld was corroded by NaCl liquids and lifted and broken, it would be deeply corroded towards the aluminum matrix, and formed many and deep gullies or pits, which became the main corrosion mechanism of rapid joint failure.
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图 1 铝钢电磁脉冲焊接原理
Figure 1. Principle of electromagnetic pulse welding with aluminum to steel. (a) impacting process with aluminum plate to steel plate; (b) particles flow at the collision moment
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图 4 盐雾腐蚀试样焊缝断面SEM观察区域
Figure 4. SEM observation zone of weld section of salt spray corrosion sample
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图 5 不同腐蚀周期下焊缝断口形貌
Figure 5. Fracture morphology of weld under different corrosion periods. (a) aluminum plate; (b) steel plate
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图 6 焊件盐雾腐蚀性能变化情况
Figure 6. Properties variation of salt spray corrosion of weldment. (a) shear strength; (b) corrosion rate and corrosion weight loss
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图 7 不同腐蚀周期下铝侧焊缝腐蚀形貌
Figure 7. Corrosion morphology of aluminum weld under different corrosion periods
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图 11 碰撞瞬时金属表面的粒子特征
Figure 11. Particles characteristics at the instantaneous impact metal surface. (a) particles of surface metal; (b) moving velocity of particles
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图 12 焊缝结束位置金属粒子分布特征
Figure 12. Distribution characteristics of metal particles at the end of weld. (a) weld at aluminum side; (b) weld at steel side
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图 13 铝钢电磁脉冲焊接接头腐蚀机理
Figure 13. Corrosion mechanism of welded joint by electromagnetic pulse with aluminum to steel. (a) initial corrosion position of welded joint; (b) corrosion failure process of the weld
表 1 6061铝合金和304不锈钢化学成分(质量分数，%)
Table 1 Chemical compositions of 6061 aluminum alloy and 304 stainless steel
材料 Cr Mn Mg Ni Si Zn Fe Al 6061 0.04 ~ 0.35 0.15 0.8 ~ 1.2 — 0.4 ~ 0.8 0.25 0.7 余量 304 0.4 ~ 0.8 ≤ 2.0 — 8.0 ~ 11.0 0.4 ~ 0.8 — 余量 — 
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