Preparation of SiCp/2009 Aluminum Matrix Composites and Their Corrosion Behavior under Acidic Salt Spray

HU Haochen; WANG Yong; JIANG Yan; GUO Quanzhong; WANG Chuan

doi:10.7643/issn.1672-9242.2025.08.014

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Equipment Environmental Engineering ›› 2025, Vol. 22 ›› Issue (8) : 108-120. DOI: 10.7643/issn.1672-9242.2025.08.014

Ships and Marine Engineering Equipment

Preparation of SiCp/2009 Aluminum Matrix Composites and Their Corrosion Behavior under Acidic Salt Spray

HU Haochen¹, WANG Yong², JIANG Yan¹, GUO Quanzhong^2,*, WANG Chuan^2,*

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Abstract

The work aims to investigate the protective performance of micro-arc oxidation (MAO) technology on silicon carbide aluminum matrix composites (SiCp/Al) in acidic polluted marine environments, and to improve the microstructure, density, thickness and corrosion resistance of MAO films by optimizing the pulse frequency (f) and electrolyte composition (sodium phosphate/sodium silicate mass ratio, i.e., phosphorus-silicon ratio). A MAO film was prepared by orthogonal experimental design, and different phosphorus-silicon ratios (1 : 2, 1 : 5, 1 : 10) and pulse frequencies (200 Hz, 250 Hz, 300 Hz) were selected, the morphology of the film was analyzed by scanning electron microscopy (SEM), the thickness of the film was measured by eddy current thickness gauge, and the corrosion resistance was evaluated by electrochemical impedance spectroscopy (EIS) and acid salt spray test (ASS). When the phosphorus-silicon ratio was 2 : 1, the thickness of the films reached the maximum value (63.8 μm), and the density was the best. When the pulse frequency was 250 Hz, the film structure was the most dense, and deviation from this frequency (200/300 Hz) led to the loosening of the film structure. The acid salt spray test showed that when the phosphorus-silicon ratio was 1 : 2, the structural stability of the film was the best. There is no obvious SiC reinforcement phase in the MAO film, indicating that the reinforcement phase is oxidized or shed during the growth of the film, resulting in the reduction of the compactness of the film. Since phosphate and aluminum ions are more likely to precipitate, the deposition of AlPO₄ is promoted by increasing the phosphorus-silicon ratio in the electrolyte, thereby improving the density of the film. In addition, the balance between deposition and sintering can be controlled by a reasonable frequency, resulting in the best possible compactness of the film. In the acidic salt spray environment, the MAO film of SiCp/Al is pitted due to the initiation of pores, and the penetration of Cl⁻ into the interface of the film/substrate causes the dissolution of the substrate metal, and the volume expansion of the corrosion products causes stress, which eventually leads to the peeling of the film.

Key words

aluminum matrix composites / MAO / pulse frequency / acidic salt spray / phosphorus-silicon ratio

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HU Haochen, WANG Yong, JIANG Yan, GUO Quanzhong, WANG Chuan. Preparation of SiCp/2009 Aluminum Matrix Composites and Their Corrosion Behavior under Acidic Salt Spray[J]. Equipment Environmental Engineering. 2025, 22(8): 108-120 https://doi.org/10.7643/issn.1672-9242.2025.08.014

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