Corrosion of Magnesium Alloys: A Review

This article introduces the paper ["Corrosion of Magnesium Alloys: A Review"] published by ["International Journal of Multidisciplinary and Current Research"].

1. Overview:

• Title: Corrosion of Magnesium Alloys: A Review
• Author: Prashant Sinha
• Publication Year: 2023
• Publishing Journal/Academic Society: International Journal of Multidisciplinary and Current Research
• Keywords: Magnesium alloys, Corrosion characteristics etc.

2. Abstracts or Introduction

Magnesium alloys are gaining popularity in aircraft and transportation technologies due to their high strength-to-weight ratio. However, their application is limited by corrosive properties, unlike aluminum alloys. This paper investigates the corrosion processes of magnesium and aims to establish a foundation for developing new alloys with enhanced corrosion resistance. Magnesium is a lightweight metal suitable for diverse applications. Despite their superior strength-to-weight ratio, magnesium alloys are not as widely used as aluminum alloys due to corrosion issues. This study explores the principles and underlying reasons for magnesium alloy corrosion, emphasizing the importance of understanding corrosion processes for developing alloys with improved corrosion characteristics.

3. Research Background:

Background of the Research Topic:

Magnesium alloys are increasingly attractive for lightweight applications, particularly in the aviation and transportation sectors, owing to their exceptional strength-to-weight ratio. However, the inherent susceptibility to corrosion presents a significant obstacle to their broader utilization, especially when compared to aluminum alloys. This corrosion issue is identified as the primary impediment to the widespread adoption of magnesium alloys.

Status of Existing Research:

While magnesium alloys possess desirable properties such as excellent stiffness/weight ratios and ease of casting, their corrosion resistance remains a critical concern. Existing research acknowledges that corrosion is a primary problem that needs to be addressed to expand the applications of magnesium alloys. The paper highlights that "The processes of magnesium corrosion are investigated in this research, which also sets the framework for the development of novel alloys with improved corrosion characteristics."

Necessity of the Research:

A comprehensive understanding of magnesium corrosion processes is essential for the advancement of new alloy designs. The development of alloys exhibiting superior corrosion characteristics is contingent upon a solid grasp of the fundamental processes governing corrosion in magnesium. As stated in the paper, "It is crucial for the development of new alloys to have a solid understanding of the processes of corrosion, since this provides the foundation for the creation of alloys with superior corrosion characteristics [3]."

4. Research Purpose and Research Questions:

Research Purpose:

The primary research purpose is to investigate the corrosion processes of magnesium alloys. This investigation aims to provide a framework that can guide the development of novel magnesium alloys with improved corrosion characteristics. The paper explicitly states, "The processes of magnesium corrosion are investigated in this research, which also sets the framework for the development of novel alloys with improved corrosion characteristics."

Key Research:

The key research areas include understanding the principles of magnesium alloy corrosion and exploring the underlying reasons for this phenomenon. The study delves into various aspects of corrosion behavior, including galvanic corrosion, intergranular corrosion, localized corrosion, and corrosion mechanisms.

Research Hypotheses:

While not explicitly stated as hypotheses, the research operates under the implicit understanding that a deeper understanding of magnesium corrosion mechanisms will enable the design of magnesium alloys with enhanced resistance to corrosion. The paper suggests that by investigating corrosion processes, it is possible to identify strategies for improving the corrosion characteristics of magnesium alloys.

5. Research Methodology

Research Design:

This paper is a review article. The research design is based on a comprehensive literature review of existing studies and publications related to the corrosion of magnesium alloys.

Data Collection Method:

Data collection involved gathering information from published research papers, articles, and handbooks related to magnesium alloy corrosion. The author synthesized existing knowledge to provide a comprehensive overview of the topic.

Analysis Method:

The analysis method employed is qualitative, involving the synthesis and interpretation of information gathered from the literature. The review analyzes and summarizes the current understanding of magnesium corrosion, categorizing different types of corrosion and their mechanisms.

Research Subjects and Scope:

The research subject is magnesium alloys and their corrosion behavior. The scope of the review encompasses various aspects of magnesium corrosion, including properties and applications of magnesium alloys, corrosion behavior in different environments, different types of corrosion (galvanic, intergranular, localized), corrosion mechanisms, and thermodynamics of corrosion.

6. Main Research Results:

Key Research Results:

• Properties and Applications of Mg alloys: Magnesium has low density, hexagonal form, and specific lattice parameters (a = 3.20 A°, c = 5.20 A°, and c/a = 1.624). It is used in various applications, primarily as castings in aerospace and transportation, and as an alloying element. Die cast magnesium is used in computer disk drives and magnetic card readers [8-25].
• Corrosion Behaviour: Magnesium has poor corrosion resistance, especially with metallic impurities or corrosive electrolytes like Cl- ions [37-39]. Oxide coating provides some protection in rural, industrial, and maritime settings. Magnesium alloys are more resistant to atmospheric corrosion than mild steel. Cast alloy AZ91 shows higher salt spray resistance than aluminum and steel die. High purity alloys like AZ91E are significantly more corrosion resistant in salt water. Corrosion morphology varies with environmental conditions, with atmospheric corrosion being broader and submerged corrosion more confined [40-41]. Commercial quality magnesium corrosion is transgranular, while pure magnesium corrosion is non-uniform [40-41].
• Galvanic Corrosion: Magnesium alloys have higher resistance to galvanic corrosion than other metals. Galvanic corrosion can occur due to potential difference, conductivity, polarizability, area ratio of cathode to anode, and distance between them.
• Intergranular Corrosion: Magnesium and its alloys are resistant to intergranular corrosion. Corrosion occurs at grain borders, not penetrating inwards [4, 18].
• Localized Corrosion: Magnesium is susceptible to pitting corrosion in neutral or alkaline salt solutions due to its low free corrosion potential.
• Corrosion Mechanisms: Corrosion processes are rooted in the reactivity of individual component phases. Pure magnesium corrosion involves reactions producing magnesium hydroxide and hydrogen gas [42-45].
• Overall Corrosion Reactions: The overall corrosion reaction is Mg+2H2O→ Mg(OH)2+H2 [4]. This is expressed as anodic reaction (Mg → Mg2+ +2e), cathodic reaction (2H2O+2e→ H2+2OH¯), and product formation (Mg2++2OH¯→ Mg(OH)2).
• Thermodynamics: Magnesium has the lowest standard potential among engineering metals (Figure 1). In chloride solution, corrosion potential is -1.7 Vnhe. Magnesium hydroxide (Mg(OH)2) or magnesium oxide (MgO) film formation affects corrosion potential.

Analysis of presented data:

The paper presents an electromotive force series in Figure 1, illustrating the standard potential of magnesium compared to other metals. This data supports the discussion on the thermodynamic aspects of magnesium corrosion, highlighting its high reactivity. The review synthesizes findings from various studies to analyze the factors influencing magnesium corrosion and the mechanisms involved.

Figure Name List:

• Fig. 1. Electromotive force series [1-3].

7. Conclusion:

Summary of Key Findings:

This review summarizes the corrosion behavior of magnesium alloys, highlighting their susceptibility to corrosion despite their advantageous strength-to-weight ratio. Key findings include the influence of impurities, environmental conditions, and alloy composition on corrosion resistance. Different types of corrosion, such as galvanic, intergranular, and localized corrosion, are discussed, along with the underlying corrosion mechanisms and thermodynamic considerations. The importance of passivation in improving corrosion resistance is emphasized.

Academic Significance of the Study:

This study provides a comprehensive handbook-level review of magnesium alloy corrosion, consolidating existing knowledge and offering a structured understanding of the complex phenomena involved. It serves as a valuable resource for researchers and engineers in materials science and engineering, particularly those focusing on magnesium alloy development and corrosion mitigation.

Practical Implications:

The review underscores the critical need to address corrosion issues to expand the practical applications of magnesium alloys, especially in structural and demanding environments. The insights provided can guide the development of new alloying strategies and surface treatments to enhance the corrosion resistance of magnesium alloys, thereby enabling their wider adoption in various industries, including aerospace and transportation.

Limitations of the Study and Areas for Future Research:

As a review article, this study is limited by the scope of existing literature. While it provides a broad overview, specific details of individual studies and experimental methodologies are not extensively covered. Future research should focus on developing innovative methods to improve the passivation of magnesium alloys and exploring new alloying elements and processing techniques to enhance corrosion resistance. Further investigation into the long-term corrosion behavior of newly developed magnesium alloys in diverse operational environments is also warranted. The paper notes that "Improving the protective instinct of the passivation coating has proven to be the only method that has been successful in producing a magnesium alloy with a corrosion rate that is significantly lower than the inherent corrosion rate that is measured by the weight loss of magnesium, which is 0.3 mm/y."

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9. Copyright:

• This material is "Prashant Sinha"'s paper: Based on "Corrosion of Magnesium Alloys: A Review".
• Paper Source: https://doi.org/10.14741/ijmcr/v.11.1.10

This material was created to introduce the above paper, and unauthorized use for commercial purposes is prohibited.
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