review · RSC Advances
Aluminium alloys are widely utilised in diverse sectors because of their high strength-to-weight ratio. This strength is typically attained through heat treatments and the addition of specific alloying elements, which generate second-phase intermetallic particles. Although these intermetallic compounds enhance mechanical strength, they play a dominant role in making aluminium alloys susceptible to corrosion. A detailed review examines the electrochemical and galvanic corrosion characteristics of major intermetallic phases commonly present in aluminium alloys, including various copper, magnesium, silicon, iron, lithium, and zinc compounds. Key behaviours discussed include galvanic polarity reversal and particle self-dissolution. Furthermore, the survey outlines current limitations in electrochemical characterisation methods, identifies critical research gaps, and highlights future development prospects in understanding these corrosion dynamics.
Aluminium alloys are critical materials across transport, construction, and engineering owing to their lightness and strength. However, unexpected corrosion can compromise structural integrity and lead to premature component failure. Understanding how microscale secondary phases corrode, switch polarities, or self-dissolve helps engineers and materials scientists design more durable alloys and better predict maintenance requirements in harsh operating environments.
The work focuses on early-stage, fundamental metallurgical mechanisms rather than a direct commercial product. Metallurgists, alloy manufacturers, and materials engineers can use these insights into intermetallic corrosion, polarity reversal, and self-dissolution to guide the design of more corrosion-resistant aluminium compositions. Because the findings represent a review of foundational electrochemical behaviour and characterisation limitations, practical deployment remains at an early, pre-commercial stage of materials research.
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Aluminum alloys are widely sought for different applications due to their high strength-to-weight ratio. Most often this increased strength of the alloy is achieved by specific alloying elements and heat treatment processes which give rise to second phases intermetallic particles (IMPs) also known as intermetallic compounds (IMCs). These second phases play a dominant role in the corrosion susceptibility of aluminum alloys. This review provides a systematic survey of the electrochemical, and galvanic corrosion behavior of IMPs in the context of aluminum alloys. A discussion of the electrochemical/galvanic corrosion behavior of selected/important intermetallic compounds that are commonly found in aluminum alloys such as the Q-phase (Al<sub>4</sub>Cu<sub>2</sub>Mg<sub>7</sub>Si<sub>8</sub>), π-phase (Al<sub>8</sub>Mg<sub>3</sub>FeSi<sub>6</sub>), θ-phase (Al<sub>2</sub>Cu), S-phase (Al<sub>2</sub>CuMg), the β-phase (Mg<sub>2</sub>Si), β-phase (Al<sub>3</sub>Mg<sub>2</sub>), δ (Al<sub>3</sub>Li), η-phase (MgZn<sub>2</sub>), and β-phase (Al<sub>3</sub>Fe) is provided. In addition, the limitations in the electrochemical characterization of intermetallic compounds, the research gap, and prospects are also provided in addition to the phenomenon of galvanic polarity reversal and self-dissolution of IMPs.
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DOI: 10.1039/d4ra06070a
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