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Atmospheric corrosion behavior of 6xxx Al alloys

in Qatar State
Conference Paper February 2015

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5 authors, including:
Mostafa Hussien Sliem

Aboubakr M. Abdullah

Qatar University

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Available from: Mostafa Hussien Sliem

Retrieved on: 27 June 2016

Aluminum alloys in the 6000 series [Al Mg Si - Cu] are widely used for the construction of aircraft structures, yacht, bicycle, frames and machinery applications. It showed a general high corrosion resistant although the capability of intergranular corrosion [IGC], due to the presence of Si and Cu elements [1, 2]. There are many theories which explained the mechanism and the behavior of IGC and its effect on the grain boundaries [3-6].
Aluminum alloys in the 6000 series [Al Mg Si - Cu] are widely used for the construction of aircraft structures, yacht, bicycle, frames and machinery applications. It showed a general high corrosion resistant although the capability of intergranular corrosion [IGC], due to the presence of Si and Cu elements [1, 2]. There are many theories which explained the mechanism and the behavior of IGC and its effect on the grain boundaries [3-6].

Mostafa Sliem,1 Aboubakr M. Abdullah,1 Adel M. A. Mohamed,1 Shaikha Al Remaihi,2 Demian Roulston,2Roy Johnson2
1Center for Advanced Materials, Qatar University Doha 2713, Qatar.
2Technology research office, Qatar Petroleum
Corresponding authors emails: aboubakr_2@yahoo.com; adel.mohamed25@yahoo.com

Al 6000 [Al-Mg-Si-Cu] series are widely used in oil field for (1)
frames, (2) tanks, (3) pipelines and machinery applications. They
showed a relatively high corrosion resistant except for the
intergrainular corrosion [IGC],.
(1)

(2)

A comparison between the surface morphologies of Al coupons before and after

atmospheric exposure time of 6 months. It can be seen that there are a significant
change in color. Also, some corrosion products and pits are formed in the different
regions (surface, crevice & welding). The intensity of the corrosion products and
pits can be noted in Halul Island.

(3)

Depth, size and number of pits for the collected Al 6063

specimens at different sites using image analyser
Pit depth (m)

Site
Min

Max

Average

No of Pits,

Av. Mouth

Pits

area (m2)
11878.4

Desert

0.03

0.08

0.054

26

Dukhan

0.05

0.11

0.08

104

189850

I. Mesaieed

0.06

0.13

0.095

152

132256

Halul

0.08

0.15

0.11

242

101791

S. Mesaieed

0.1

0.19

0.14

53

412851

Ras Laffan

0.1

0.23

0.17

398

756459

North Field

0.14

0.28

0.22

71

1075690

Depth, size and number of pits for the collected Al6082

specimens at different sites using image analyser

Visual observation of collected Al 6063 specimens after 6 Months from

different sites

A. Establishing a materials map (Corrosion Atlas) for different

regions in Qatar. Al 6063 and Al 6082 are part of this map.
B. Studying the forms of corrosion for the two Al alloys at
different sites.
C. Studying the corrosion rate, pit aspect ratio and pit density of
the Al alloys after different times of exposure at different
atmospheric condition.

Pit depth (m)

Site
Min

Max

Average

No of Pits,

Av. Mouth

Pits

area (m2)

Desert

0.05

0.1

0.07

58

6707

Dukhan

0.06

0.15

0.11

130

28226

I. Mesaieed

0.06

0.17

0.13

240

29517

Halul

0.1

0.2

0.15

490

21259

S. Mesaieed

0.1

0.23

0.18

180

133327

Ras Laffan

0.14

0.26

0.21

609

137419

North Field

0.18

0.31

0.27

110

1739820

Ras laffan has the highest pit density, North field has the lowest
aspect ratio and the highest corrosion rate.
12
65

11

60

Al 6063 after 6 months exposure test

Al 6082 after 6 months exposure test

Intergrainular corrosion is clearly observed in Al 6063 alloy in different

environments as seen in industrial sites and marine sites

Pits density, Pits/mm2

55

10

50

-6 -1
Aspect ratio, X 10 m

Visual observation of collected Al 6082 specimens after 6 Months from

different sites

45
40
35
30
25
20
15
10

Al 6063 after 6 months exposure test

Al 6082 after 6 months exposure test

8
7

6
5
4
3
2

Two type of Al alloys (Al 6063 and Al

6082) with 3 mm thick are used in our
research. The coupons are welded from
edge to edge at 30 mm away from the
edge facing the fixing hole [1,2]. The
elemental composition is shown in the
table below.

0
Desert

Dukhan

I.Mesaieed

Halul

S.Mesaieed Ras lffan

North field

Desert

Dukhan I.Mesaieed

Site code

Halul

S.Mesaieed Raslffan North field

Site code

22

Al 6063 after 6 months exposure test

Al 6082 after 6 months exposure test

-3

Corrosion rate, X 10 mpy

20
18
16

14
12
10
8
6
4
2
0

Desert

Dukhan

I.Mesaieed

Halul

S.Mesaieed Ras lffan

North field

Site code

Typical Chemical Composition of Al alloys

Alloy Cu

Mg

Si

Fe

Mn

Ti

Cr

Zn Others

(A) Pits density, (B) Aspect ratio and (C) The rate of
corrosion of Al alloys at different sites

Al

Al
6063

0.10 0.45-0.9 0.2-0.6 0.35 0.10

0.10 0.10 0.10

0.15

Balance

0.10 0.6 -1.2 0.7-1.3 0.50 0.4 -1 0.10 0.25 0.20

0.05

Balance

BSEM and elemental mapping of Al 6063 alloy, exposed to Dukhan site

for 6 months.

Al
6082

1. It is clear that the number and the size of pits depend on

the aggressiveness of the environment.
2. The corrosion rate for Al 6082 alloy is higher than Al 6063
alloy at the same corrosive environment.
3. Al alloys has the tendency for IGC in industrial and marine
sites.
4. Sulfur compounds may be responsible for crevice
propagation more than the chloride ions in Al alloys
5. The pitting corrosion rate depends on the chloride ion
concentrations.

Macroscopic and microscopic analyses for the collected Al

alloys from different sites were done. Furthermore, the pit depth
measurements, oxide layer thickness examinations with Back
Scattered and Electrochemical measurements were also carried
out.

Average Meteorological data of stations according to ISO 9223

from July to December

Stations

Max Temp Min Temp

RH (%)

Chlorides

Sulfur

(mg/m2/day)

(mg/m2/day)

Dew point

Air borne

Intergrainular images and EDX of Al 6063 alloy, exposed to North

field site for 6 months.

Wind speed

(oC)

(oC)

Desert

35.5

22

52

3.17

25.89

14.5

132.7

10.3

Dukhan

31.9

23.9

63.9

5.22

61.07

19.9

98.57

9.4

I. Mesaieed

34.5

23

56

8.74

55.11

17.5

133

8.7

particles

Electrochemical tests for Al 6063 specimens show that the collected

specimens have slopes higher than blank. Desert site has the highest slope
due to building of the oxide layer
-0.46
-0.48

27.4

67

5.34

184

22.1

75.97

10.5

S. Mesaieed

34.5

23.5

57

15.15

33.8

17.5

133

8.7

-0.2

-0.3

-0.56
-0.58

Al 6082 + 0.25 M Na2SO4

-0.60

Desert
Dukhan

-0.62

Industrial Mesaieed
Halul
Seaside Mesaieed
Ras laffan
North field

-0.64

Ras Laffan

33.5

22

61.7

13.2

26.72

17.9

124

10

North field

32

25.5

68.1

25.28

166.7

22

87

7.35

-0.4

-0.54

-0.66
-0.68

-0.70
-0.0000018 -0.0000012 -0.0000006 0.0000000 0.0000006
2

log i/A, A/cm

0.0000012

E, mV (SCE)

31.2

-0.52

E, mV (SCE)

Halul

-0.50

The authors would like to express their grateful

acknowledgement for financial and kind support received
from QP company. A special thank for Prof. Mariam AlMaadeed (the head of CAM, QU) and Mr. Saqer AlShahwani (Head of Operations Research, QP) and Qatar
meteorology department for their support

-0.5

Al 6082 + 0.25 M Na2SO4

-0.6

Desert
-0.7

Dukhan

Industrial Mesaieed
Halul
Seaside Mesaieed
Ras laffan
North field

-0.8
-0.9
-1.0

-10

-9

-8

-7

log i/A, A/cm

-6

-5

-4

A) Linear and B) Tafel polarization of Al 6063 alloy in 0.25M

Na2SO4 after exposed to different sites for 6 months, at room
temperature

1. ASTM G4-1 : 2008 Standard Guide for Conducting

Corrosion Tests in Field Applications
2. ASTM G1-03 : 2011 Standard Practice for Preparing,
Cleaning, and Evaluating Corrosion Test Specimens
3. ASTM G46-94 : 2005 Standard Guide for Examination
and Evaluation of Pitting Corrosion