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The cold rolled aluminium alloy (AA6061-T6) and its friction-stir welded joints (with varied tool-tilt angle and joint configuration) were investigated for their corrosion performance using a corrosion immersion test in two stages. First, the influence of corrosion conditions on the performance of base metal was investigated using the design-of-experiments approach with the central composite design of response surface methodology. Among the three input corrosion variables (namely time, temperature and NaCl-concentration) selected at three levels each, the contribution of temperature to corrode the base metal was found to the order of ≈50%, followed by time (21%) and NaCl-concentration (7%). Further, parameters were optimised to attain minimum and maximum corrosion rate conditions. In the second-stage, the optimised corrosion conditions were used to study the corrosion behaviour of the welded joints. Among all welds, the single-pass joint fabricated with 0° tilt angle showed minimum corrosion rate but possessed 96% higher mass-loss compared to the base metal. Moreover, the corrosion rate was found to increase with the increase in tool-tilt angle, as-well-as with the change in joint configuration from single-pass to double-pass. The optical and scanning electron microscopy revealed the pitting and intergranular corrosion to be the dominating corrosion mechanisms for the base metal and welded joints.

Evaluating the corrosion behaviour of AA6061-T6 alloy and its friction stir welded joints