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

Research output: Contribution to journalArticlepeer-review

2 Scopus citations

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 languageEnglish (US)
Pages (from-to)608-620
Number of pages13
JournalJournal of Manufacturing Processes
Volume70
DOIs
StatePublished - Oct 2021

All Science Journal Classification (ASJC) codes

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

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