Age-hardening behavior, corrosion mechanisms, and passive film structure of nanocrystalline Al-V supersaturated solid solution.

• Synthesis of a nanocrystalline Al-5at.%V alloy with high solid solubility of V by high-energy ball milling • Study on the age hardening behavior of the ball milled Al-V alloy • Corrosion behavior as a function of age hardening time and temperature • Study of the passive film and pits using transmission electron microscope • Microstructural features causing passive film breakdown and subsequent pit growth or repassivation The effect of age-hardening on microstructure, hardness, and corrosion of an Al-5at.%V alloy, produced using high-energy ball milling and subsequent cold compaction, has been investigated. The alloy exhibited a grain size below 100 nm and extremely high solid solubility of V in Al (3.1 at.%). The age-hardening was carried out at 150, 200, and 250 °C. The peak-aged condition of 150 °C demonstrated the highest hardness—transpired from grain refinement, precipitation, and solid solution hardening. The corrosion resistance of the Al-5at.%V alloy was studied as a function of aging conditions. The peak-aged condition retained the corrosion resistance while it deteriorated in the over-aged condition. Nonetheless, the corrosion resistance of the ball-milled Al alloys in all the aging conditions was superior to that of pure Al. The passive film structure and origin of corrosion were studied using scanning/transmission electron microscopy (S/TEM). The high corrosion resistance of the alloy was attributed to the V enrichment at the film/metal interface and deposition of V on the cathodic phases, which suppresses the dissolution of Al within the pit and therefore promotes repassivation in the early stages of corrosion. [Display omitted] [ABSTRACT FROM AUTHOR]