Corrosion behavior in aluminum/galvanized steel resistance spot welds and self-piercing riveting joints in salt spray environment

Bo Pan; Hui Sun; Shun Li Shang; Weiling Wen; Mihaela Banu; Joseph C. Simmer; Blair E. Carlson; Nannan Chen; Zi Kui Liu; Zhuoyuan Zheng; Pingfeng Wang; Jingjing Li

doi:10.1016/j.jmapro.2021.08.052

Corrosion behavior in aluminum/galvanized steel resistance spot welds and self-piercing riveting joints in salt spray environment

Bo Pan, Hui Sun, Shun Li Shang, Weiling Wen, Mihaela Banu, Joseph C. Simmer, Blair E. Carlson, Nannan Chen, Zi Kui Liu, Zhuoyuan Zheng, Pingfeng Wang, Jingjing Li

Industrial and Enterprise Systems Engineering

Research output: Contribution to journal › Article › peer-review

Abstract

This paper underlined the corrosion behavior of aluminum alloy/galvanized steel joints fabricated by resistance spot welding (RSW) and self-piercing riveting (SPR) exposed to different salt-spray cycles. It was found that the crevice generated by different joining methods has an important impact on corrosion behavior. Compared with the RSW joint, less corrosion happened on the coupled regions in SPR joints because of the higher local pH value resulted from the smaller crevice. The crevice, however, has less impact on the types of corrosion products. Galvanic corrosion happened in the coupled region for both RSW and SPR joints. The Pourbaix diagram explained the stable corrosion products of Al and Zn[sbnd]Fe alloy, which are Al₂O₃, ZnO, and Fe₃O₄. Additional corrosion products observed from the experiment included α-Al(OH)₃, Ca₄Al₂(CO₃)(OH)₁₂(H₂O)₅, Zn₅(OH)₈Cl₂(H₂O), Zn₅(CO₃)₂(OH)₆, and Fe₂(OH)₂(CO₃), which can be understood by considering the metastable corrosion products, Pourbaix diagram, and possible chemical reactions.

Original language	English (US)
Pages (from-to)	608-620
Number of pages	13
Journal	Journal of Manufacturing Processes
Volume	70
DOIs	https://doi.org/10.1016/j.jmapro.2021.08.052
State	Published - Oct 2021

Keywords

Aluminum
Corrosion products
Galvanic corrosion
Galvanized steel
XRD

ASJC Scopus subject areas

Strategy and Management
Management Science and Operations Research
Industrial and Manufacturing Engineering

Online availability

10.1016/j.jmapro.2021.08.052

Library availability

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@article{14a7d80f899e42b78202b411e8fa6cdb,

title = "Corrosion behavior in aluminum/galvanized steel resistance spot welds and self-piercing riveting joints in salt spray environment",

abstract = "This paper underlined the corrosion behavior of aluminum alloy/galvanized steel joints fabricated by resistance spot welding (RSW) and self-piercing riveting (SPR) exposed to different salt-spray cycles. It was found that the crevice generated by different joining methods has an important impact on corrosion behavior. Compared with the RSW joint, less corrosion happened on the coupled regions in SPR joints because of the higher local pH value resulted from the smaller crevice. The crevice, however, has less impact on the types of corrosion products. Galvanic corrosion happened in the coupled region for both RSW and SPR joints. The Pourbaix diagram explained the stable corrosion products of Al and Zn[sbnd]Fe alloy, which are Al2O3, ZnO, and Fe3O4. Additional corrosion products observed from the experiment included α-Al(OH)3, Ca4Al2(CO3)(OH)12(H2O)5, Zn5(OH)8Cl2(H2O), Zn5(CO3)2(OH)6, and Fe2(OH)2(CO3), which can be understood by considering the metastable corrosion products, Pourbaix diagram, and possible chemical reactions.",

keywords = "Aluminum, Corrosion products, Galvanic corrosion, Galvanized steel, XRD",

author = "Bo Pan and Hui Sun and Shang, {Shun Li} and Weiling Wen and Mihaela Banu and Simmer, {Joseph C.} and Carlson, {Blair E.} and Nannan Chen and Liu, {Zi Kui} and Zhuoyuan Zheng and Pingfeng Wang and Jingjing Li",

note = "Funding Information: This work was financially supported by the U. S. Department of Energy via Award No. DE-EE0008456 and the US National Science Foundation Civil, Mechanical and Manufacturing Innovation Grant No. 1651024 . Publisher Copyright: {\textcopyright} 2021 The Society of Manufacturing Engineers",

year = "2021",

month = oct,

doi = "10.1016/j.jmapro.2021.08.052",

language = "English (US)",

volume = "70",

pages = "608--620",

journal = "Journal of Manufacturing Processes",

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TY - JOUR

T1 - Corrosion behavior in aluminum/galvanized steel resistance spot welds and self-piercing riveting joints in salt spray environment

AU - Pan, Bo

AU - Sun, Hui

AU - Shang, Shun Li

AU - Wen, Weiling

AU - Banu, Mihaela

AU - Simmer, Joseph C.

AU - Carlson, Blair E.

AU - Chen, Nannan

AU - Liu, Zi Kui

AU - Zheng, Zhuoyuan

AU - Wang, Pingfeng

AU - Li, Jingjing

N1 - Funding Information: This work was financially supported by the U. S. Department of Energy via Award No. DE-EE0008456 and the US National Science Foundation Civil, Mechanical and Manufacturing Innovation Grant No. 1651024 . Publisher Copyright: © 2021 The Society of Manufacturing Engineers

PY - 2021/10

Y1 - 2021/10

N2 - This paper underlined the corrosion behavior of aluminum alloy/galvanized steel joints fabricated by resistance spot welding (RSW) and self-piercing riveting (SPR) exposed to different salt-spray cycles. It was found that the crevice generated by different joining methods has an important impact on corrosion behavior. Compared with the RSW joint, less corrosion happened on the coupled regions in SPR joints because of the higher local pH value resulted from the smaller crevice. The crevice, however, has less impact on the types of corrosion products. Galvanic corrosion happened in the coupled region for both RSW and SPR joints. The Pourbaix diagram explained the stable corrosion products of Al and Zn[sbnd]Fe alloy, which are Al2O3, ZnO, and Fe3O4. Additional corrosion products observed from the experiment included α-Al(OH)3, Ca4Al2(CO3)(OH)12(H2O)5, Zn5(OH)8Cl2(H2O), Zn5(CO3)2(OH)6, and Fe2(OH)2(CO3), which can be understood by considering the metastable corrosion products, Pourbaix diagram, and possible chemical reactions.

AB - This paper underlined the corrosion behavior of aluminum alloy/galvanized steel joints fabricated by resistance spot welding (RSW) and self-piercing riveting (SPR) exposed to different salt-spray cycles. It was found that the crevice generated by different joining methods has an important impact on corrosion behavior. Compared with the RSW joint, less corrosion happened on the coupled regions in SPR joints because of the higher local pH value resulted from the smaller crevice. The crevice, however, has less impact on the types of corrosion products. Galvanic corrosion happened in the coupled region for both RSW and SPR joints. The Pourbaix diagram explained the stable corrosion products of Al and Zn[sbnd]Fe alloy, which are Al2O3, ZnO, and Fe3O4. Additional corrosion products observed from the experiment included α-Al(OH)3, Ca4Al2(CO3)(OH)12(H2O)5, Zn5(OH)8Cl2(H2O), Zn5(CO3)2(OH)6, and Fe2(OH)2(CO3), which can be understood by considering the metastable corrosion products, Pourbaix diagram, and possible chemical reactions.

KW - Aluminum

KW - Corrosion products

KW - Galvanic corrosion

KW - Galvanized steel

KW - XRD

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M3 - Article

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SN - 1526-6125

VL - 70

SP - 608

EP - 620

JO - Journal of Manufacturing Processes

JF - Journal of Manufacturing Processes

ER -

Corrosion behavior in aluminum/galvanized steel resistance spot welds and self-piercing riveting joints in salt spray environment

Abstract

Keywords

ASJC Scopus subject areas

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