Investigation of corrosion behavior of Al–TiO2 nanocomposite produced using air plasma spray and accumulative roll bonding method

Abstract This work is an attempt to study the Al–TiO 2 nanocomposite properties applying accumulative roll bonding process. For this purpose, nano Titania powder was first coated on aluminum foil by air plasma spraying process. The nanocomposite was then fabricated in one, two, three, five, and seven cycles by ARB. To investigate the effect of ARB process cycles on an Al-5% wt. TiO 2 nanocomposite, characterization tests including XRD, quantitative XRD analysis by MAUD software, FESEM, EDS, electrochemical impedance, and TAFEL polarization tests were performed on the samples. The results indicate that the crystallite size reduced from 156 to 31 nm and the dislocation density quadrupled in the composite. The results of XRD analysis showed an increase in the dislocation density in the composite when the number of cycles increases. The reduction of crystallite size and increase of the grain boundaries have caused a sudden increase in the dislocation density. As the ARB cycle increases, the local porosity decreases and the local cracks due to the separation of the titanium sprayed droplets disappear in the matrix phase, and the reinforcing phase has more diffusion in the matrix. With the increase of ARB cycles, the percentage of titanium and oxygen elements on the surface was decreasing, but they remained until the last cycle. Among the non-rolled and rolled samples in different cycles, ARBed samples after 1 cycle and 5 cycles had not only the lowest and highest corrosion current densities but also the highest and lowest total resistance (R t ), respectively. This indicates max corrosion resistance due to the decrease in defect and porosity resulting from plasma spray and min corrosion resistance as a result of formation of galvanic cell between Al-matrix and Ti-reinforcing particles, respectively.