2nd Project

A SEMINAR ON
CORROSION STUDIES ON FSW WELDMENTS
•Prepared By:- • Guides :-

•Kapoor Krunal .A •Dr . S. N . Soman
•Roll No:- 930 & •Dr .V. V . Mathane
•Singh Ashutosh .R •Mr. Sunil. Kahar
•Roll No:-945 •Mr . L .V. Kamble
METALLURGICAL & MATERIALS ENGINEERING DEPARTMENT
FACULTY OF TECHNOLOGY AND ENGINEERING

THE M.S UNIVERSITY OF BARODA
MAY-2013
CONTENTS
• Introduction
• Literature survey
• Experimental work
• Result and Discussion
• Conclusions
• References
Objectives
• Microstructure analysis of AA 6101 aluminum alloy FSW
welded, Identification of welding zone (TMAZ & HAZ) for
corrosion studies.

• To study and analyze pitting corrosion behavior of FSW
weldments of aluminum alloy AA 6101 in 3.5Nacl as
environment using Potentiodynamic cyclic polarization test.
Introduction
Literature review
• Friction stir welding (FSW) is solid-state joining process.
• Friction stir welding (FSW) is relatively new technique which

was invented by the Welding Institute of UK in early nineties.
• FSW is considered as a green technology due to its energy

efficiency , environment , friendliness, and versatility.
• The basic concept of FSW is remarkably simple;- A non-

consumable rotating tool with a specially designed pin and
shoulder is inserted into the abutting edges of sheets or plates to
be joint & traversed along the line of joint.
FSW Set up
Merits of FSW
 Metallurgical :
 Solid phase process

 Low distortion of work piece
 Good dimensional stability and repeatability
 No loss of alloying elements
 Excellent metallurgical properties in the joint area
 Fine microstructure
 Absence of cracking
 Joined by fasteners
• Environmental benefits

• No shielding gas required
• No surface cleaning required
• Eliminate grinding wastes
• Eliminate solvents required for degreasing
• Consumable materials saving, i.e rugs, filler metal , shielding gases
• Energy benefits
• Improved materials use allows reduction in weight

• Energy needed is only 2.5% of the energy needed for a laser weld
Demerits of FSW
• Exit hole left when tool is withdrawn.
• Large down forces required with heavy-duty clamping

necessary to hold the plates together.
• Less flexible than manual and arc processes ,often slower

traverse rate than some fusion welding techniques although
this may be offset if fewer welding passes are required.
Applications of FSW
• Shipbuilding and marine industries

• Aerospace industry
• Railways
• Land transportation
• Electric motor housings
• Refrigeration panels
• Cooking equipment and kitchens
Important welding parameters
• Tool rotation & traverse speed
• Tool tilt & plunge depth
• Tool design
Microstructure Features for FSW
Schematic cross–section of a typical FSW weld showing four distinct

zones:(A) Base metal, (B) heat–affected, (C) thermo mechanically affected
and (D) stirred (nugget) zone
Corrosion
• Corrosion means the electrochemical reaction between the materials,
usually a metal & its environment that produces a deterioration of the
material and its properties.
• Most commonly, this means a loss of electrons of metals reacting with

water and oxygen. This type of damage typically produces oxides and/or
salts of the original metal.
• Corrosion can also refer to the degradation of ceramic materials as well as

the dis-colouration and weakning of polymers by sun’s ultraviolet light.
Corrosion rate Expression
• Corrosion rate has been expressed in various ways such as percentage weight loss,
milligrams per square centimeter per day .
• The expression mills per year are the most desirable way of the expressing corrosion
rates.
m p y = 534x W
D x Ax T
Where,
W= weight loss , mg
D= density of specimen, gm per cubic centimeter
A = Expose area of specimen , sq. inch
T = Exposure time , hr.
Polarization:-
• The deviation from equilibrium potential is called polarization is called
polarization. Polarization can be conveniently divided into two
different types, activation & concentration polarization.
• Activation polarization refers to an electrochemical process that is

controlled by the reaction sequence at the metal- electrolyte interface.
• While, Concentration polarization refers to electrochemical reactions

that can be controlled by the diffusion species from the electrolyte to
the metal- electrolyte interface.
• Passivity :- The phenomenon of passivity refers to the loss of

chemical reactivity experienced by certain metals & alloys become
essentially inert & act as if they were noble metals such as platinum
and gold.
• The Material used for making FSW weldments during project is aluminium
and its various alloys.
Aluminium is mainly used of the grade :- AA 6101
Composition of AA 6101 Aluminum Alloy
Elements Wt %
Al 98.89
Mg 0.6
Si 0.5
Potentiostatic & Potentiodynamic Test
• Electrode potential is change at regular interval with
potentiostat and associate current is measure with
milli ammeter after it reaches to its steady state value.
• Suitable for anodic polarization measurements.
Galvanostatic & Galvanodynamic Test

• Current is increase at regular interval or continuously &
resulting specimen potential is measure after it reaches to its
steady state value.
• Suitable for both anodic & cathodic polarization
measurements.
Experimental work
.
• Plan of work - Extension of the earlier work done on the AA 6101
Al alloy materials using FSW with the variables.

• Based on zone analysis we prepare window of 5mm x 5mm
on TMAZ and nugget and rest portion of the sample masking
is done using mask tape.
• After that Cyclic polarization test is carried on the given

sample in 3.5 % Nacl solution as environment using Gammry
software.
• Here cyclic polarization test is carried out on the FWS weldments

for measuring Pitting potential, corrosion rate, corrosion potential,
corrosion current and also predicts its behaviour under given
environment.
Experimental details
• First of all we grind the received sample & then polish it using
emery papers of different sizes using kerosene during polishing.
• After final polishing we applied etchant as hydrogen fluoride

on the surface of welded portion. Then microstructure analysis is
carried out on the welded portion of sample using microscope.
• By observing microstructure we are able to analyze various

welded zone such as HAZ, TMAZ , Nugget, & Base metal portion.
Microstructure Analysis
• Metallography of weld sample
• polishing
• Fine polishing with emery papers lubricated with kerosene 1/0,2/0,3/0.4/0
• Diamond polishing on velveteen cloth with use of alumina powder & kerosene
• Etchant : ( in dilute form)
Hydrofluoric acid : 6 ml
Hydrochloric acid : 12ml
Nitric acid : 22 ml
Distilled water : 60 ml Immersion time : 1 to 3 min
Microstructure of AA 6101 Al alloy
AA 6101 T6 , Base metal, 250x AA6101 T6 ,basemetal,SEM,250x

microstructural zones of sample E1
microstructural zones of sample H1
microstructural zones of sample M1
Cyclic polarization
method
Purpose of cyclic polarization study
 Study the pitting behavior of an alloy
 Determination of pitting potential
 Determination of corrosion potential
 Study the passivation behavior of alloy
 Study polarization (anodic & cathodic) behavior of alloy

Standard of cyclic polarization study
• Using Potentiostat -Gammry Reference 600 .
• ASTM G-61, "Standard Test Method for Conducting Cyclic

Polarization Measurements for Localized Corrosion
Susceptibility of Iron-, Nickel- or Auminium Based Alloys” .
• Corrosive Environments- 3.5 % NACL Solution.

Cyclic polarization test Setup
Masking of Samples
Window for exposure= 5 mm x 5 mm
Sequence of operation of corrosion testing
My Gamry DC
Experiment
Framwork Corrosion
Cyclic polarization
Get Setup Run

Operating Parameters for Cyclic polarization test
Sr.No Cyclic polarization test
1 Initial Voltage=0.5 V
2 Forward Scan=2.5 mV
3 Reverse Scan=2.5 mV
4 Final Voltage=1.0 V
5 Apex Current= 1000 mA / cm2
6 Sample area = 0.25 cm2
7 Density = 7.87 gm / cm2

8 Equivalent weight = 22.92 gm
Setup of cyclic polarization testing
Interpretation of the Result of cyclic polarization testing
Negative hysteresis
• Epit >Ecorr
• pitting will occur but damage

passive film will repaired &
protecting it from further
corrosion.
Interpretation of the Result of cyclic polarization testing
Positive hysteresis
• Epit <Ecorr
• pitting will occur and

corrosion rate will increase
because damage passive film
will not repaired.
Cyclic polarization curve for base metal in 3.5Nacl
Cyclic polarization curve for E1-T in 3.5Nacl
Cyclic polarization curve for H1-T in 3.5Nacl
Cyclic polarization curve for M1-T in 3.5Nacl
Cyclic polarization curve for E1-H in 3.5Nacl
Cyclic polarization curve for H1-H in 3.5Nacl
Cyclic polarization curve for M1-H in 3.5Nacl
Result & Discussion
Result of Cyclic polarization experiments:
Sample code Icorr Ecorr Epit Corrosion rate
(A) (mV) (mV) (mpy)
Base metal 0.067 -600.0 -842.8 115.0e-3
E1-T 0.156 -804.0 -866.9 267.2e-3

E2-T 1.090 -762.0 -861.9 1.877
E3-T 0.993 -724.0 -827.9 1.704
H1-T 0.639 -1180.0 -821.2 1.097

H2-T 75.20 -710.0 -944.3 129.1
H3-T 0.128 -723.0 -820.4 219.2e-3
M1-T 0.0858 -767.0 -934.4 147.1e-3

M2-T 0.255 -737.0 -917.2 437.8e-3
M3-T 1.080 -768.0 -848.4 1.852
Sample code Icorr Ecorr Epit Corrosion rate
(A) (mV) (mV) (mpy)
E1-H 0.430 -1040.0 -838.7 737.7e-3
E2-H 2.060 -822.0 -883.3 3.538
E3-H 3.610 -783.0 -829.6 6.198
H1-H 0.461 -830.0 -931.9 790.2e-3

H2-H 0.605 -1010.0 -865.1 1.038
H3-H 1.300 -733.0 -813.9 2.238
M1-H 0.214 -858.0 -831.1 366.4e-3

M2-H 0.227 -932.0 -880.6 390.0e-3
M3-H 0.411 -1000.0 -854.0 705.7e-3
Conclusions
1. FSW welding results into formation of distinguished zones
namely nugget, TMAZ, HAZ.
2. HAZ (heat affected zones) and TMAZ (thermo mechanically

affected zones) are of more of the interest as they incorporate
the most thermal and mechanical stress which make them most
likely to be attacked by environment.
3. In case of HAZ the passivity film may be or may not be

repairable, it depends on the heat input & extent of heat
distribution.
4. From cyclic polarization studies,
a. # The potentiodynamic polarization curve having negative

hysteresis loop, makes the sample corrosion resistant.
b. # The potentiodynamic polarization curve having positive
hysteresis loop, results into tendency of pitting, which
continuously grow.
5. Among all the samples welded with rotational speed of 1070

rpm shows pitting resistance. (M1-H, M2-H, M3-H)
6. From overall observation, it can also be concluded that at all

rotational speed and at low welding speed, pitting resistance is
observed. (E1-H, H1-T, H1-H, M1-T, M1-H)
7. In general high rotational & low welding speed results into less
distorted HAZ & TMAZ and hence better pitting resistance.
References
1. http:// www.friction stir welding. Com/ met/
2. http:// www.friction stirwelding.Com/met/
3. Great Britain Patent Application No.9125978.8,W. M. T h o m
a s, , December 1991.
4. http://www.twi.co.uk/j32k/unprotected/band_1/fswintro.Ht
ml
5. Friction Stir Welding and Processing, R. S. M i s h r a, M. W.
M a h o n e y, ASM International, Ohio, USA, p. 1 (2007).
6. http://www.aluminum.org/
7. Corrosion Engineering Third edition, by: Mars G. Fontana.
8. Welding Technology, by: R. S. Parmar.
9. ASM handbook for metallography and microstructure, Vol- 9
10.Friction stir welding and Processing, R.S. Mishra, M.W. Mahoney, ASM
International, Ohio, USA, P. 1(2007)
11. ASM Handbook on corrosion.
12. http:// www.friction stir welding. Com/ met/ Aluminium.html.
13. Welding Fundamentals, Chevron Corporation.
14. Handbook of Corrosion Engineering, Pierre R. Roberge.
15. Thesis on Studies & Effect of Tool design & Process parameters on quality
of Friction Stir Welding of Aluminum alloy.
16. http://corrosion_ doctors.org/ corrosion. History/Eight.html
17. Mechanical properties of aluminum 6101- T6 welds by Friction stir welding
and metal inert gas welding, by c. Hamilton S. dymek, m.blicharski.
18. The microstructure and mechanical properties of friction stir welded Al-Zn-
Mg alloy in as welded and heat treated conditions, By: R.K.R. Singh.
19. An Introduction to Metallic Corrosion and its Prevention, By:
Raj Narayan.
20. Microstructure characterization and mechanical properties in
friction stir welding of aluminum and titanium dissimilar alloys,
by, Y.C.Chen *, K. Nakata, Joining and welding Research
Institute, Osaka University.
21.An Introduction to Electrometallurgy & corrosion, By: Sharan &
Narayan.
22. Pdf file on Cyclic Polarization Test.
23. Pdf on Fundamentals of Potentiodynamic studies.
24. Corrosion and corrosion control_ An Introduction to Corrosion
Science & Engineering- Herbert H. Uhlig. John Wiley & Sons
Inc; New York.
25 .www.researchstudies on corrosion.com.
26.Welding Technology for Engineers, By: Baldev raj& V Shankar.

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A SEMINAR ON

CORROSION STUDIES ON FSW WELDMENTS

•Prepared By:- • Guides :-

METALLURGICAL & MATERIALS ENGINEERING DEPARTMENT

FACULTY OF TECHNOLOGY AND ENGINEERING

• Friction stir welding (FSW) is solid-state joining process.

• Friction stir welding (FSW) is relatively new technique which

• FSW is considered as a green technology due to its energy

• The basic concept of FSW is remarkably simple;- A non-

 Solid phase process

• Improved materials use allows reduction in weight

• Exit hole left when tool is withdrawn.

• Large down forces required with heavy-duty clamping

• Less flexible than manual and arc processes ,often slower

• Shipbuilding and marine industries

• Tool rotation & traverse speed

• Tool tilt & plunge depth

Schematic cross–section of a typical FSW weld showing four distinct

• Most commonly, this means a loss of electrons of metals reacting with

• Corrosion can also refer to the degradation of ceramic materials as well as

• Activation polarization refers to an electrochemical process that is

• While, Concentration polarization refers to electrochemical reactions

• Passivity :- The phenomenon of passivity refers to the loss of

Aluminium is mainly used of the grade :- AA 6101

Composition of AA 6101 Aluminum Alloy

Galvanostatic & Galvanodynamic Test

• After that Cyclic polarization test is carried on the given

• Here cyclic polarization test is carried out on the FWS weldments

• After final polishing we applied etchant as hydrogen fluoride

• By observing microstructure we are able to analyze various

• Fine polishing with emery papers lubricated with kerosene 1/0,2/0,3/0.4/0

• Etchant : ( in dilute form)

AA 6101 T6 , Base metal, 250x AA6101 T6 ,basemetal,SEM,250x

 Study the pitting behavior of an alloy

 Determination of pitting potential

 Determination of corrosion potential

 Study the passivation behavior of alloy

 Study polarization (anodic & cathodic) behavior of alloy

• Using Potentiostat -Gammry Reference 600 .

• ASTM G-61, "Standard Test Method for Conducting Cyclic

• Corrosive Environments- 3.5 % NACL Solution.

Get Setup Run

Sr.No Cyclic polarization test

7 Density = 7.87 gm / cm2

• pitting will occur but damage

• pitting will occur and

E1-T 0.156 -804.0 -866.9 267.2e-3

H1-T 0.639 -1180.0 -821.2 1.097

M1-T 0.0858 -767.0 -934.4 147.1e-3

H1-H 0.461 -830.0 -931.9 790.2e-3

M1-H 0.214 -858.0 -831.1 366.4e-3

2. HAZ (heat affected zones) and TMAZ (thermo mechanically

3. In case of HAZ the passivity film may be or may not be

4. From cyclic polarization studies,

a. # The potentiodynamic polarization curve having negative

5. Among all the samples welded with rotational speed of 1070

6. From overall observation, it can also be concluded that at all

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