Mg-Al系镁合金及稀土元素（Ce，La）合金化后微观结构和腐蚀行为的研究
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摘要
镁及镁合金的比强度大、相对机械性能高、阻尼性和切削性好、导热性及减振性好、而且易于回收,具有广阔的应用前景,成为21世纪最重要最有发展潜力的商用轻质材料,被誉为绿色工程材料。然而作为结构材料的镁合金其主要不足之一是成本高,且镁合金的耐蚀性差成为制约其发展的重要因素。稀土元素合金化是提高镁合金耐蚀性的有效途径之一,改善了镁合金的微观结构和腐蚀产物,进而影响了镁合金的腐蚀行为。作为工业常用的Mg-Al系合金,其腐蚀行为和腐蚀防护的研究也日益受到电化学工作者的重视。本文以Mg-Al系镁合金(AM60,AZ91)为研究对象,采用多种电化学测试方法和物理表征相结合,详细研究了添加稀土元素对Mg-Al系镁合金在本体和薄液膜条件下微观结构和腐蚀行为的影响,并考察了稀土相γ在镁合金腐蚀过程中的作用。本文的研究内容如下：
采用析氢测试和电化学手段相结合,如开路电位测试、极化曲线、电化学阻抗谱等,研究了Cl-浓度对AM60镁合金在本体溶液中腐蚀行为的影响,结果表明随Cl-浓度的增加,镁合金的耐蚀性下降。腐蚀形貌和产物研究结果表明Cl-浓度升高促进镁合金局部腐蚀的发生和表面膜的破裂,验证了电化学阻抗谱中低频区扩散弧随Cl-浓度升高向感抗弧转变的过程。结合电化学和物理表征结果,我们建立了Cl-浓度对镁合金在本体溶液中腐蚀行为影响机制的模型,NaCl浓度升高时,更多的Cl-吸附在镁合金表面,与腐蚀产物中的Mg(OH)2发生反应生成可溶性MgCl2,加速镁基体的溶解和表面膜的快速水化,同时由于CO2扩散到电解液中受限,形成的不溶性碳酸镁化合物相对较少,因而镁合金腐蚀越来越严重。
在SF6和CO2混合气体保护下,采用已知配比金属原料并加入稀土元素Ce和La,我们成功制备了不同含量的稀土镁合金。稀土元素改变了镁合金的微观结构,形成了富含稀土和Al元素的针状稀土相γ，β相的数量减少。SKPFM的结果表明,γ相的伏特电势相对较正,作为腐蚀阴极相存在,γ相与α相的电势差相对于p相与α相的要小,电势分布更加均匀,因而减小了镁合金的微电偶腐蚀趋势。稀土镁合金的腐蚀产物膜比较致密,含有稀土和Al的氧化物和/或氢氧化物,抑制了镁合金的进一步腐蚀。稀土元素合金化提高了AM60镁合金的耐蚀性。然而由于大量的稀土相的生成,会与α相形成了更多的腐蚀微电偶对,因而稀土元素的过量添加导致镁合金腐蚀性能的再次恶化。
大气腐蚀的本质是发生在薄液膜下的电化学反应,因而研究镁合金在薄液膜下的腐蚀行为对于深入了解其大气腐蚀机制具有重要意义。镁合金在薄液膜下的腐蚀行为和其在本体溶液下的不同。阴极极化曲线结果表明随液膜厚度降低,镁合金的阴极电流密度减小,阴极反应受到抑制。电化学阻抗谱的结果表明,随液膜厚度降低,镁合金的耐蚀性增加,当液膜厚度为100μm左右时,镁合金的腐蚀速率和其在本体溶液中的相差不大。对于稀土镁合金而言,阴极极化曲线在阴极电势远离开路电位300mV左右时出现第二段阴极斜率,表明此时存在与AM60合金不同的动力学区域(II)；当液膜厚度为200-300μm时,EIS低频区容抗弧和感抗弧交替出现,这是一价镁离子的阳极反应和稀土相γ上阴极反应相互竞争的结果。而对AM60合金而言,在所有情况下,低频区仅仅出现感抗行为。
腐蚀产物的成分和结构是影响镁合金腐蚀行为的重要因素之一。镁合金在薄液膜下的腐蚀产物和腐蚀形貌和其在本体溶液中不同。我们采用多种物理表征手段(如XRD、FTIR、SEM等)详细研究了稀土镁合金AMRE1和AM60在薄液膜条件下的腐蚀产物组成和腐蚀形貌特征。结果表明液膜厚度对同种镁合金腐蚀产物的成分影响不大。在薄液膜下镁合金的腐蚀形貌有两个特征区域：腐蚀严重区,其腐蚀产物主要是Mg(OH)2和镁的碳酸盐化合物；腐蚀轻微区,其腐蚀产物主要是后者。在薄液膜条件下,稀土镁合金的腐蚀产物富含稀土和Al元素,形成网状结构,对镁基体提供了一定的保护性。此外,AM60和稀土镁合金AMRE1腐蚀形貌最明显的区别是：在本体溶液,AM60合金是均匀腐蚀,AMRE1合金是局部腐蚀。随着液膜厚度的降低,镁合金的点蚀孕育受到抑制,但点蚀生长加速。
镁合金的腐蚀与表面膜(或腐蚀产物层)的破坏和修复作用息息相关。镁合金腐蚀起源于无膜区,无膜区内发生的点蚀是镁合金的主要腐蚀形式。镁合金无膜区活性点的孕育、产生和发展受到C1-浓度和表面膜成分的影响。扫描电化学显微镜(SECM)可以原位检测到这些具有活性的微小区域及其变化。在浸泡初期,AM60和AZ91D镁合金的活性点随Cl-浓度的升高而逐渐增多,蚀点的活性也不断增强。对于稀土镁合金而言,由于致密表面膜的存在,高活性点在浸泡过程中再次钝化,且蚀点的活性受Cl-浓度影响相对较弱,在浸泡初期主要表现为微观形貌的变化。据AM60镁合金划痕上线性扫描结果和腐蚀形貌可知, Cl-浓度升高加速了表面膜的溶解,促进了镁合金腐蚀。与AM60相比,稀土镁合金划痕上线性扫描曲线随时间的变化不大,划痕上电流峰值和宽度受Cl-的影响相对较小。结合划痕上腐蚀形貌的结果可知,稀土镁合金表面膜更加致密,对镁合金的保护性相对较强,因而划痕上电流峰值其随Cl-浓度的影响不大。
Called as green engineering material, magnesium and magnesium alloy has been used in many applications and become the most important and potential lightweight material in21Century due to its special properties, such as high specific strength, good relative mechanical properties, good damping property and castability, perfect thermal conductivity and vibration reduction, easy to recycle. However, as construction material, one of its main drawbacks is high cost. Moreover, their poor corrosion resistance in comparison with other metals has greatly limited their further utilizing. It is well known that that addition of rare earth (RE) elements is an effective way to improve the corrosion resistance of magnesium alloy. The microstructure and corrosion product of magnesium alloy is improved after rare earth addition, then the physical changes has an influence on the corrosion behavior of magnesium alloy. As most used inducstrical Mg-Al alloy, its corrosion behavior and corrosion protect has attracted more and more attentions. In this dissertation, the corrosion behavior of Mg-Al magnesium alloy (AM60and AZ91) in bulk solution and under thin electrolyte layer (TEL) successfully monitored via electrochemical methods with the aid of home-made equipment. The main contents are listed as follows:
The influence of chloride ion concentration on the corrosion behavior of AM60magnesium alloy in bulk solution has been investigated by hydrogen evolution and electrochemical test, such as open circuit potential (OCP) curves, polarization curves, electrochemical impedence spectroscopy (EIS) and so on. The results indicate that corrosion resistance decreases with increasing Cl-concentration. The more concentrated NaCl solution promotes initiation of localized corrosion and the breakdown of surface film as shown in corrosion morphology and corrosion product, proving that diffusion tail at low frequencies in EIS plots was transforned to inductive arc with Cl-concentration increasing. A corrosion model is proposed to explain the influence of chloride ion concentration on the corrosion behavior of magnesium alloy, implying that more and more chloride ions adsorb on the surface of magnesium alloy in high concentrated NaCl solution and react with Mg(OH)2to form soluble MgCl2, corrosion is promoted in the corrosion zone resulting in higher hydration of the surface components. Meanwhile, the diffusion of CO2to the electrolyte is limited and the amount of insoluble corrosion product containning CO32-is relativly low and corrosion of magneisum becomes more and more serious.
New magneiusm alloys AMRE were prepared in a crucible furnace under the shelter of CO2and SF6with cerium (Ce) and lanthanum (La) in a water cooled metallic model. Their corrosion behavior was evaluated by hydrogen evolution and electrochemical methods. The microstructure of magnesium alloy is optimized after rare earth element addition with new intermetallic compounds y forms and the fraction of (3phase decreases. The results of SKPFM indicate that y phase has more active potential as cathodic phase in the microgavanic couple. The potential difference between y phase and a phase is less than that between β phase and a phase. Moreover, the potential distribution of AMRE1is more even compared with AM60, indicating less micro-galvanic corrosion. Corrosion product film which is enriched in RE and Al element and more compact and thin, on the RE-containning alloy surface is another key factor to the inhibition of further corrosion. The corrosion resistance of AM60was improved by RE addition. However, the content of rare earth element has a significant effect on the corrosion behavior of magnesium alloy, the excess addition of RE deteriorates corrosion resistance due to more y phases formed and the number of microgavanic couple between y and a phases was increased.
The nature of atmospheric corrosion, which occurs under thin electrolyte film or even adsorbed layers, is electrochemical reaction between micro-anodes and micro-cathodes. Thus, investigation on corrosion behavior under thin electrolyte layers (TEL) plays an improtant role in understanding atmospheric corrosion of magnesium alloy. The corrosion behavior of magnesium alloy under thin electrolyte layers is different with that in the bulk solution.The results of cathodic polarizaiton curves indicate cathodic current density is depressed and cathodic reaction is inhibited with TEL decreasing. The EIS measurement domenstrates that corrosion resistance is enhanced by TEL thinning. Whereas, the corrosion resistance in the vicinity of100μm is closed to or even lower than that in bulk solution. As RE addition as concerned, there is the second kinetic region in the cathodic polarization curves of AMRE1alloy when cathodic potential shifed300mV with respect to open circuit potential (OCP); and there are capactive loops and inductive arcs altnatively appeared at LFs under200-300μm thickness, which results from the competition between reaction of Mg+on the local anodic area located where film broke down and reaction of H+on the cathodic surface of intermetallic compound (y phase). However, an inductive loop always showes up at LFs for AM60no matter how thick the electrolyte layer is.
The composition and structure of corrosion product is very improtant in corrosion behavior of magnesium alloys. The corrosion product and corrosion morphology was respectively investigated by XRD, EDS. FTIR and SEM as complement to the corrosion behavior of AMRE1under TEL compared with AM60. The results indicate that the composition of corrosion products is not affected by TEL for the same type of magnesium alloy. The corrosion morphology of AMRE1magnesium alloy under TEL has two characteristics excpect at the vicinity of100μm: one is the severely localized corroded section, the other one is " unaffected area". The corrosion product are Mg(OH)2and compounds containing CO32-in seriously corroded section and only latter one is present in "unaffected area". In the condition of TEL, the corrosion product of AMRE1is enriched in RE and Al element, forms a skeleton structure to inhibit the corrison progress. Moreover, the corrosion morphology of AMRE1discloses the localized corrosion under bulk solution, different with AM60in uniform corrosion form. The pit initiation is inhibited under TEL and the pit growth is accelerated.
Corrosion of magnesium is related to the destruction and repassivation of its surface film (or corrosion production film). Corrosion of magnesium is initiated from free-film region where the pit corrosion is the main corrosion form. The pregnance and growth of acitive points in free-film region is affected by the concentration of Cl-and the composition of surface film. These small active regions or points can be detected by Scanning Electrochemistry Microscopy (SECM). In the initial of immersion, the number and electrochemical activity of active points on AZ91and AM60magnesium alloy increase with Cl-concentration. While, high acitve points on magnesium alloy AMCel disappear in the immersion due to its dense surface film. Moreover, the Cl-concentration has a weak impact on the electrochemical activity of active points on AMCel magnesium alloy. The SECM images mainly reflect the surface morphology of magnesium alloy. According to the result of line scan across the scratch on AM60magnesium and corrosion morphology, dissolution of surface film is accelerated with Cl-concentration increasing. Compared with AM60, the line scan curves of scratch on AMCel magnesium slightly change with immersion time. Meanwhile, the strength and width of current peak across the scratch is slightly influenced by Cl-concentration. The result of corrosion morphology of scracth on AMCel magnesium alloy indicate that surface film of AMCel is more dense and provides strong protection for substrate and weakly affected by Cl-concentration.
采用析氢测试和电化学手段相结合,如开路电位测试、极化曲线、电化学阻抗谱等,研究了Cl-浓度对AM60镁合金在本体溶液中腐蚀行为的影响,结果表明随Cl-浓度的增加,镁合金的耐蚀性下降。腐蚀形貌和产物研究结果表明Cl-浓度升高促进镁合金局部腐蚀的发生和表面膜的破裂,验证了电化学阻抗谱中低频区扩散弧随Cl-浓度升高向感抗弧转变的过程。结合电化学和物理表征结果,我们建立了Cl-浓度对镁合金在本体溶液中腐蚀行为影响机制的模型,NaCl浓度升高时,更多的Cl-吸附在镁合金表面,与腐蚀产物中的Mg(OH)2发生反应生成可溶性MgCl2,加速镁基体的溶解和表面膜的快速水化,同时由于CO2扩散到电解液中受限,形成的不溶性碳酸镁化合物相对较少,因而镁合金腐蚀越来越严重。
在SF6和CO2混合气体保护下,采用已知配比金属原料并加入稀土元素Ce和La,我们成功制备了不同含量的稀土镁合金。稀土元素改变了镁合金的微观结构,形成了富含稀土和Al元素的针状稀土相γ，β相的数量减少。SKPFM的结果表明,γ相的伏特电势相对较正,作为腐蚀阴极相存在,γ相与α相的电势差相对于p相与α相的要小,电势分布更加均匀,因而减小了镁合金的微电偶腐蚀趋势。稀土镁合金的腐蚀产物膜比较致密,含有稀土和Al的氧化物和/或氢氧化物,抑制了镁合金的进一步腐蚀。稀土元素合金化提高了AM60镁合金的耐蚀性。然而由于大量的稀土相的生成,会与α相形成了更多的腐蚀微电偶对,因而稀土元素的过量添加导致镁合金腐蚀性能的再次恶化。
大气腐蚀的本质是发生在薄液膜下的电化学反应,因而研究镁合金在薄液膜下的腐蚀行为对于深入了解其大气腐蚀机制具有重要意义。镁合金在薄液膜下的腐蚀行为和其在本体溶液下的不同。阴极极化曲线结果表明随液膜厚度降低,镁合金的阴极电流密度减小,阴极反应受到抑制。电化学阻抗谱的结果表明,随液膜厚度降低,镁合金的耐蚀性增加,当液膜厚度为100μm左右时,镁合金的腐蚀速率和其在本体溶液中的相差不大。对于稀土镁合金而言,阴极极化曲线在阴极电势远离开路电位300mV左右时出现第二段阴极斜率,表明此时存在与AM60合金不同的动力学区域(II)；当液膜厚度为200-300μm时,EIS低频区容抗弧和感抗弧交替出现,这是一价镁离子的阳极反应和稀土相γ上阴极反应相互竞争的结果。而对AM60合金而言,在所有情况下,低频区仅仅出现感抗行为。
腐蚀产物的成分和结构是影响镁合金腐蚀行为的重要因素之一。镁合金在薄液膜下的腐蚀产物和腐蚀形貌和其在本体溶液中不同。我们采用多种物理表征手段(如XRD、FTIR、SEM等)详细研究了稀土镁合金AMRE1和AM60在薄液膜条件下的腐蚀产物组成和腐蚀形貌特征。结果表明液膜厚度对同种镁合金腐蚀产物的成分影响不大。在薄液膜下镁合金的腐蚀形貌有两个特征区域：腐蚀严重区,其腐蚀产物主要是Mg(OH)2和镁的碳酸盐化合物；腐蚀轻微区,其腐蚀产物主要是后者。在薄液膜条件下,稀土镁合金的腐蚀产物富含稀土和Al元素,形成网状结构,对镁基体提供了一定的保护性。此外,AM60和稀土镁合金AMRE1腐蚀形貌最明显的区别是：在本体溶液,AM60合金是均匀腐蚀,AMRE1合金是局部腐蚀。随着液膜厚度的降低,镁合金的点蚀孕育受到抑制,但点蚀生长加速。
镁合金的腐蚀与表面膜(或腐蚀产物层)的破坏和修复作用息息相关。镁合金腐蚀起源于无膜区,无膜区内发生的点蚀是镁合金的主要腐蚀形式。镁合金无膜区活性点的孕育、产生和发展受到C1-浓度和表面膜成分的影响。扫描电化学显微镜(SECM)可以原位检测到这些具有活性的微小区域及其变化。在浸泡初期,AM60和AZ91D镁合金的活性点随Cl-浓度的升高而逐渐增多,蚀点的活性也不断增强。对于稀土镁合金而言,由于致密表面膜的存在,高活性点在浸泡过程中再次钝化,且蚀点的活性受Cl-浓度影响相对较弱,在浸泡初期主要表现为微观形貌的变化。据AM60镁合金划痕上线性扫描结果和腐蚀形貌可知, Cl-浓度升高加速了表面膜的溶解,促进了镁合金腐蚀。与AM60相比,稀土镁合金划痕上线性扫描曲线随时间的变化不大,划痕上电流峰值和宽度受Cl-的影响相对较小。结合划痕上腐蚀形貌的结果可知,稀土镁合金表面膜更加致密,对镁合金的保护性相对较强,因而划痕上电流峰值其随Cl-浓度的影响不大。
Called as green engineering material, magnesium and magnesium alloy has been used in many applications and become the most important and potential lightweight material in21Century due to its special properties, such as high specific strength, good relative mechanical properties, good damping property and castability, perfect thermal conductivity and vibration reduction, easy to recycle. However, as construction material, one of its main drawbacks is high cost. Moreover, their poor corrosion resistance in comparison with other metals has greatly limited their further utilizing. It is well known that that addition of rare earth (RE) elements is an effective way to improve the corrosion resistance of magnesium alloy. The microstructure and corrosion product of magnesium alloy is improved after rare earth addition, then the physical changes has an influence on the corrosion behavior of magnesium alloy. As most used inducstrical Mg-Al alloy, its corrosion behavior and corrosion protect has attracted more and more attentions. In this dissertation, the corrosion behavior of Mg-Al magnesium alloy (AM60and AZ91) in bulk solution and under thin electrolyte layer (TEL) successfully monitored via electrochemical methods with the aid of home-made equipment. The main contents are listed as follows:
The influence of chloride ion concentration on the corrosion behavior of AM60magnesium alloy in bulk solution has been investigated by hydrogen evolution and electrochemical test, such as open circuit potential (OCP) curves, polarization curves, electrochemical impedence spectroscopy (EIS) and so on. The results indicate that corrosion resistance decreases with increasing Cl-concentration. The more concentrated NaCl solution promotes initiation of localized corrosion and the breakdown of surface film as shown in corrosion morphology and corrosion product, proving that diffusion tail at low frequencies in EIS plots was transforned to inductive arc with Cl-concentration increasing. A corrosion model is proposed to explain the influence of chloride ion concentration on the corrosion behavior of magnesium alloy, implying that more and more chloride ions adsorb on the surface of magnesium alloy in high concentrated NaCl solution and react with Mg(OH)2to form soluble MgCl2, corrosion is promoted in the corrosion zone resulting in higher hydration of the surface components. Meanwhile, the diffusion of CO2to the electrolyte is limited and the amount of insoluble corrosion product containning CO32-is relativly low and corrosion of magneisum becomes more and more serious.
New magneiusm alloys AMRE were prepared in a crucible furnace under the shelter of CO2and SF6with cerium (Ce) and lanthanum (La) in a water cooled metallic model. Their corrosion behavior was evaluated by hydrogen evolution and electrochemical methods. The microstructure of magnesium alloy is optimized after rare earth element addition with new intermetallic compounds y forms and the fraction of (3phase decreases. The results of SKPFM indicate that y phase has more active potential as cathodic phase in the microgavanic couple. The potential difference between y phase and a phase is less than that between β phase and a phase. Moreover, the potential distribution of AMRE1is more even compared with AM60, indicating less micro-galvanic corrosion. Corrosion product film which is enriched in RE and Al element and more compact and thin, on the RE-containning alloy surface is another key factor to the inhibition of further corrosion. The corrosion resistance of AM60was improved by RE addition. However, the content of rare earth element has a significant effect on the corrosion behavior of magnesium alloy, the excess addition of RE deteriorates corrosion resistance due to more y phases formed and the number of microgavanic couple between y and a phases was increased.
The nature of atmospheric corrosion, which occurs under thin electrolyte film or even adsorbed layers, is electrochemical reaction between micro-anodes and micro-cathodes. Thus, investigation on corrosion behavior under thin electrolyte layers (TEL) plays an improtant role in understanding atmospheric corrosion of magnesium alloy. The corrosion behavior of magnesium alloy under thin electrolyte layers is different with that in the bulk solution.The results of cathodic polarizaiton curves indicate cathodic current density is depressed and cathodic reaction is inhibited with TEL decreasing. The EIS measurement domenstrates that corrosion resistance is enhanced by TEL thinning. Whereas, the corrosion resistance in the vicinity of100μm is closed to or even lower than that in bulk solution. As RE addition as concerned, there is the second kinetic region in the cathodic polarization curves of AMRE1alloy when cathodic potential shifed300mV with respect to open circuit potential (OCP); and there are capactive loops and inductive arcs altnatively appeared at LFs under200-300μm thickness, which results from the competition between reaction of Mg+on the local anodic area located where film broke down and reaction of H+on the cathodic surface of intermetallic compound (y phase). However, an inductive loop always showes up at LFs for AM60no matter how thick the electrolyte layer is.
The composition and structure of corrosion product is very improtant in corrosion behavior of magnesium alloys. The corrosion product and corrosion morphology was respectively investigated by XRD, EDS. FTIR and SEM as complement to the corrosion behavior of AMRE1under TEL compared with AM60. The results indicate that the composition of corrosion products is not affected by TEL for the same type of magnesium alloy. The corrosion morphology of AMRE1magnesium alloy under TEL has two characteristics excpect at the vicinity of100μm: one is the severely localized corroded section, the other one is " unaffected area". The corrosion product are Mg(OH)2and compounds containing CO32-in seriously corroded section and only latter one is present in "unaffected area". In the condition of TEL, the corrosion product of AMRE1is enriched in RE and Al element, forms a skeleton structure to inhibit the corrison progress. Moreover, the corrosion morphology of AMRE1discloses the localized corrosion under bulk solution, different with AM60in uniform corrosion form. The pit initiation is inhibited under TEL and the pit growth is accelerated.
Corrosion of magnesium is related to the destruction and repassivation of its surface film (or corrosion production film). Corrosion of magnesium is initiated from free-film region where the pit corrosion is the main corrosion form. The pregnance and growth of acitive points in free-film region is affected by the concentration of Cl-and the composition of surface film. These small active regions or points can be detected by Scanning Electrochemistry Microscopy (SECM). In the initial of immersion, the number and electrochemical activity of active points on AZ91and AM60magnesium alloy increase with Cl-concentration. While, high acitve points on magnesium alloy AMCel disappear in the immersion due to its dense surface film. Moreover, the Cl-concentration has a weak impact on the electrochemical activity of active points on AMCel magnesium alloy. The SECM images mainly reflect the surface morphology of magnesium alloy. According to the result of line scan across the scratch on AM60magnesium and corrosion morphology, dissolution of surface film is accelerated with Cl-concentration increasing. Compared with AM60, the line scan curves of scratch on AMCel magnesium slightly change with immersion time. Meanwhile, the strength and width of current peak across the scratch is slightly influenced by Cl-concentration. The result of corrosion morphology of scracth on AMCel magnesium alloy indicate that surface film of AMCel is more dense and provides strong protection for substrate and weakly affected by Cl-concentration.
引文
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