Comparative corrosion characteristics of 6061 aluminum alloy in acidic and chloride-rich environments

Department of Mechanical Engineering, Covenant University, Ogun State, Nigeria

Abstract

This study investigates the corrosion behavior of 6061 aluminum alloy (6061Al) under various environmental conditions, including sulfuric acid (H₂SO₄), sodium chloride (NaCl), and their combinations. The alloy’s performance was assessed using weight loss and corrosion rate measurements over prolonged exposure periods. Results indicate that the corrosion rate in H₂SO₄ solutions decreases over time due to passive film formation, with higher concentrations exhibiting more aggressive corrosion. NaCl solutions promote localized pitting corrosion, with the severity influenced by salt concentration and time. The most significant corrosion occurred in mixed H₂SO₄/NaCl environments, demonstrating a synergistic effect of acid and chloride ions that destabilize the protective oxide layer. Statistical analysis using ANOVA revealed NaCl concentration as the primary factor influencing corrosion resistance, while prolonged exposure exacerbates degradation. The findings emphasize the necessity of controlling environmental factors to optimize the performance and durability of 6061Al in corrosive settings.