Article(id=1195733616836784262, tenantId=1146029695717560320, journalId=1189873562199433220, issueId=1195733614798357446, articleNumber=null, orderNo=null, doi=10.19710/J.cnki.1003-8817.20230384, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=research-article, receivedDate=null, receivedDateStr=null, revisedDate=null, revisedDateStr=null, acceptedDate=null, acceptedDateStr=null, onlineDate=1763014709910, onlineDateStr=2025-11-13, pubDate=1745078400000, pubDateStr=2025-04-20, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1763014709910, onlineIssueDateStr=2025-11-13, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1763014709910, creator=13701087609, updateTime=1763014709910, updator=13701087609, issue=Issue{id=1195733614798357446, tenantId=1146029695717560320, journalId=1189873562199433220, year='2025', volume='', issue='4', pageStart='1', pageEnd='72', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1763014709424, creator=13701087609, updateTime=1763015213929, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1195735730925388785, tenantId=1146029695717560320, journalId=1189873562199433220, issueId=1195733614798357446, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1195735730925388786, tenantId=1146029695717560320, journalId=1189873562199433220, issueId=1195733614798357446, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=60, endPage=63, ext={EN=ArticleExt(id=1195733617977634955, articleId=1195733616836784262, tenantId=1146029695717560320, journalId=1189873562199433220, language=EN, title=Research on Aluminum Alloy Corrosion Test, columnId=1190284220686766583, journalTitle=Automobile Technology & Material, columnName=Original article, runingTitle=null, highlight=null, articleAbstract=

To address the issue of electrochemical corrosion of steel-aluminum hybrid vehicle body, especially galvanic corrosion, corrosion test of aluminum alloy is studied to explore the influence of different steel-aluminum joining material and method, different forming process on aluminum alloy corrosion. The results show that the corrosion grade of the bolted samples is higher than that of SPR riveting due to the double effects of galvanic corrosion and crevice corrosion, whereas corrosion resistance of cast aluminum alloy is obviously lower than that of extruded profile due to segregation of components.

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为解决钢铝混合车身的电化学腐蚀问题,尤其是电偶腐蚀,对铝合金腐蚀试验进行研究,探究不同钢铝连接材料及连接方式、不同成型工艺对铝合金腐蚀的影响。结果表明:螺接样品受电偶腐蚀和缝隙腐蚀的双重影响,腐蚀等级高于SPR铆接;铸造铝合金因成分偏析问题,防腐性能明显低于挤压型材。

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李英(1982—),女,工程师,学士学位,研究方向为高分子材料。

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李英(1982—),女,工程师,学士学位,研究方向为高分子材料。

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典型铝合金零件 铝合金材料 铝合金成型工艺 与铝合金连接的零件材料 与铝合金的连接方式
轮辋 A356 铸造 普通碳钢 螺接
悬置 A380 铸造 普通碳钢 螺接
门槛边梁 6082-T6 挤压 镀锌钢 铆接
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某车型铝合金的应用情况

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典型铝合金零件 铝合金材料 铝合金成型工艺 与铝合金连接的零件材料 与铝合金的连接方式
轮辋 A356 铸造 普通碳钢 螺接
悬置 A380 铸造 普通碳钢 螺接
门槛边梁 6082-T6 挤压 镀锌钢 铆接
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试验条件 关键参数
耐久路+高环路+碎石路 总里程约为200 km
盐水路 浓度为1%的NaCl溶液,液体深度
为50 mm
盐雾舱 浓度为5%的NaCl溶液,盐雾沉降量
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高温高湿舱 温度为50 ℃,相对湿度为50%~95%,持续时间为8 h
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试验条件 关键参数
耐久路+高环路+碎石路 总里程约为200 km
盐水路 浓度为1%的NaCl溶液,液体深度
为50 mm
盐雾舱 浓度为5%的NaCl溶液,盐雾沉降量
为1~2 mL/(80 cm2·h)
高温高湿舱 温度为50 ℃,相对湿度为50%~95%,持续时间为8 h
), ArticleFig(id=1195790970903113905, tenantId=1146029695717560320, journalId=1189873562199433220, articleId=1195733616836784262, language=EN, label=null, caption=null, figureFileSmall=null, figureFileBig=null, tableContent=
序号 零部件名称 成型工艺 试验强度 锈蚀
等级
1 机舱边梁前段 挤压工艺 整车循环腐蚀60循环 3
2 门槛边梁 挤压工艺 3
3 前车架连接件 铸造工艺 5
4 后车架连接件 铸造工艺 5
5 PTC 铸造工艺 5
), ArticleFig(id=1195790971033137330, tenantId=1146029695717560320, journalId=1189873562199433220, articleId=1195733616836784262, language=CN, label=表3, caption=

不同成型工艺的铝合金整车循环盐雾试验结果

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序号 零部件名称 成型工艺 试验强度 锈蚀
等级
1 机舱边梁前段 挤压工艺 整车循环腐蚀60循环 3
2 门槛边梁 挤压工艺 3
3 前车架连接件 铸造工艺 5
4 后车架连接件 铸造工艺 5
5 PTC 铸造工艺 5
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铝合金腐蚀试验研究
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李英 , 彭华江 , 何忠树 , 张椿聆
汽车工艺与材料 | 材料应用 2025,(4): 60-63
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汽车工艺与材料 | 材料应用 2025, (4): 60-63
铝合金腐蚀试验研究
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李英, 彭华江, 何忠树, 张椿聆
作者信息
  • 重庆长安汽车股份有限公司工程研究总院, 重庆 401120
  • 李英(1982—),女,工程师,学士学位,研究方向为高分子材料。

Research on Aluminum Alloy Corrosion Test
Ying Li, Huajiang Peng, Zhongshu He, Chunling Zhang
Affiliations
  • R&D Center, Chongqing Chang’an Automobile Co., Ltd., Chongqing 401120
出版时间: 2025-04-20 doi: 10.19710/J.cnki.1003-8817.20230384
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为解决钢铝混合车身的电化学腐蚀问题,尤其是电偶腐蚀,对铝合金腐蚀试验进行研究,探究不同钢铝连接材料及连接方式、不同成型工艺对铝合金腐蚀的影响。结果表明:螺接样品受电偶腐蚀和缝隙腐蚀的双重影响,腐蚀等级高于SPR铆接;铸造铝合金因成分偏析问题,防腐性能明显低于挤压型材。

铝合金  /  防腐蚀  /  电偶腐蚀

To address the issue of electrochemical corrosion of steel-aluminum hybrid vehicle body, especially galvanic corrosion, corrosion test of aluminum alloy is studied to explore the influence of different steel-aluminum joining material and method, different forming process on aluminum alloy corrosion. The results show that the corrosion grade of the bolted samples is higher than that of SPR riveting due to the double effects of galvanic corrosion and crevice corrosion, whereas corrosion resistance of cast aluminum alloy is obviously lower than that of extruded profile due to segregation of components.

Aluminum alloy  /  Anti-corrosion  /  Galvanic corrosion
李英, 彭华江, 何忠树, 张椿聆. 铝合金腐蚀试验研究. 汽车工艺与材料, 2025 , (4) : 60 -63 . DOI: 10.19710/J.cnki.1003-8817.20230384
Ying Li, Huajiang Peng, Zhongshu He, Chunling Zhang. Research on Aluminum Alloy Corrosion Test[J]. Automobile Technology & Material, 2025 , (4) : 60 -63 . DOI: 10.19710/J.cnki.1003-8817.20230384
防腐蚀是汽车产品的关键性能,不仅用户高度关注,同时与产品安全性能强相关。随着轻量化混合车身的不断发展,铝合金作为轻量化车辆的主要金属材料,其腐蚀问题及与钢偶接后的电偶腐蚀问题研究需求越来越迫切。
本文的主要研究内容为铝合金和钢铝连接件的防腐性能。虽然铝合金的腐蚀通常以白锈为主,不易被消费者察觉,但轮辋等高可见部位的腐蚀投诉较多。本文研究铝合金及与钢连接的腐蚀机理,通过研究建立多级试验验证标准和铝合金腐蚀评价标准,以降低车用铝合金的锈蚀风险。
电偶腐蚀在车辆腐蚀中较为常见。电偶腐蚀是指电位不同的2种金属在电解质溶液中发生原电池反应,其中:电位较低的金属构成原电池的阳极,发生氧化反应,腐蚀速率增大;电位较高的金属构成原电池的阴极,发生还原反应,腐蚀速率减小,受到保护。钢铝连接件的电偶腐蚀化学反应方程式为:
阳极反应:Al-3e-=Al3+
阴极反应:O2+2H2O+4e-=4OH-
总式:4Al+3O2+6H2O=4Al(OH)3
通过分析售后数据,铝合金的主要腐蚀位置为铝合金材料与碳钢的搭接部位。悬置支架、轮辋的腐蚀位置均在异种金属的搭接处(合金与钢制结构搭接),悬置支架与螺标件搭接处、轮辋与制动盘搭接处腐蚀比较集中,搭接位置均没有密封,存在电解质(盐水)的影响,易形成电偶腐蚀回路。针对售后腐蚀调研中的重点零部件进行分析,设计如图1所示的铝合金防腐试验。
整车铝合金的应用情况如表1所示。
基于上述分析,设计铝合金防腐试验方案如下:
a. 方案1为铝合金分别与普通碳钢、镀锌钢连接的整车强化腐蚀试验;
b. 方案2为铝合金分别与普通碳钢、镀锌钢不同连接方式(螺接、自冲铆接)的整车强化腐蚀试验;
c. 方案3为不同成型工艺(挤压、铸造)铝合金的整车强化腐蚀试验。
整车强化腐蚀试验的试验条件和主要参数如表2所示。
观察铝合金与普通碳钢、镀锌钢整车盐雾循环100次后的宏观腐蚀形貌和微观腐蚀形貌,发现均形成了腐蚀坑,且铝合金的腐蚀深度大于钢材,普通碳钢的腐蚀深度大于镀锌钢。铝合金板材(6082-T6)分别与普通碳钢(DC01)、镀锌钢(DC51D+Z)螺接,经过整车盐雾循环100次后,铝合金板材(6082-T6)的腐蚀深度分别为587.23 μm和473.16 μm,如图2所示。腐蚀深度比约为1.24∶1。
分析认为,铝合金与普通碳钢、镀锌钢板螺接后发生了电偶腐蚀,由于不同金属的标准电极电位不同,电位相对较低的铝合金(铝的标准电极电位为-1.66 V)作为阳极而腐蚀加速,电位相对较高的普通碳钢(铁的标准电极电位为-0.44 V)、镀锌钢板(锌的标准电极电位为-0.76 V)作为阴极而腐蚀减缓,表明铝合金的加速腐蚀对普通碳钢、镀锌钢板起到一定的保护作用。另外,由于2种金属的电位差越大越容易发生电偶腐蚀,普通碳钢与铝合金螺接的电位差大于镀锌板与铝合金螺接的电位差,故铝合金与普通碳钢螺接的腐蚀程度较铝合金与镀锌钢板严重[1]
观察铝合金与普通碳钢、镀锌钢整车盐雾循环100次后的宏观腐蚀形貌和微观腐蚀形貌,发现均形成了腐蚀坑,且铝合金螺接的腐蚀深度大于铝合金自冲铆接的腐蚀深度,如图3所示。铝合金板材(6082-T6)分别与钢板DC01螺接和自冲铆接,经过整车循环盐雾循环100次后,铝合金板材(6082-T6)的腐蚀深度分别为579.51 μm和417.67 μm,腐蚀深度比约为1.46∶1;铝合金板材(6082-T6)分别与镀锌钢DC51D+Z螺接和自冲铆接, 经过整车循环盐雾循环100次后,铝合金板材(6082-T6)的腐蚀深度分别为397.06 μm和293.77 μm,腐蚀深度比约为1.42∶1。
对比铝合金与普通碳钢、镀锌钢螺接的腐蚀形貌与铝合金与普通碳钢、镀锌钢自冲铆接的腐蚀形貌,铝合金螺接的腐蚀程度明显高于铝合金自冲铆接,说明铝合金与普通碳钢、镀锌钢板螺接时不仅发生了电偶腐蚀,还存在缝隙腐蚀。研究表明,缝隙宽度为0.025~0.250 mm时对缝隙腐蚀最为敏感。自冲铆接的钣金间隙<0.025 mm,故自冲铆接部位很少出现缝隙腐蚀,主要为电偶腐蚀。而钢铝螺接的间隙为0.10~0.25 mm,故螺接部位受电偶腐蚀和缝隙腐蚀的共同影响,且同时出现电偶腐蚀与缝隙腐蚀联合的部位腐蚀最为严重[2]
由某车型整车腐蚀试验验证结果可知,挤压型材铝合金防腐性能(平均锈蚀等级为3)优于铸造铝合金(平均锈蚀等级为5),如表3所示。
分析认为,铝合金防腐主要依赖其表面形成的致密氧化膜,阻隔腐蚀介质,不同成型工艺会影响氧化膜的质量。铸造时,金属液与氧气反应析出氧化物,形成粗糙、不均匀的氧化膜,保护性能较差,而挤压成型可以打破铸造所形成的表面氧化膜,新的氧化膜能够在加工后的表面重新形成,更均匀致密。另外,挤压还会使合金产生加工硬化,改善微观组织,提高腐蚀电位,增强耐蚀性[3]
a. 螺接样品受电偶腐蚀和缝隙腐蚀的双重影响,腐蚀等级高于自冲铆接;铸造铝合金因成分偏析问题,防腐性能明显低于挤压型材。
b. 从国内腐蚀环境条件及用户的接受程度来看,铝合金售后腐蚀风险较低,整车防腐设计压力较小。
c. 对于海外高腐蚀环境地区,钢铝连接腐蚀需再进行系统性研究。
参考文献:
  • 重庆市技术创新与应用发展专项项目(cstc2020jscx-dxwtBX0023)
参考文献 引证文献
排序方式:
[1]
张文毓. 电偶腐蚀与防护的研究进展[J]. 全面腐蚀控制, 2018, 32(12): 51-56+122.
[2]
蔡建敏, 关蕾, 李雨, 等. 车用钢-铝合金连接的电偶腐蚀及防护[J]. 腐蚀与防护, 2022, 43(5): 1-10.
[3]
赵春花, 黄垂刚, 王康. 浅谈乘用车车身钢铝搭接两种表面处理应用[J]. 涂层与防护, 2019, 40(2): 5-9.
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doi: 10.19710/J.cnki.1003-8817.20230384
  • 首发时间:2025-11-13
  • 出版时间:2025-04-20
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重庆市技术创新与应用发展专项项目(cstc2020jscx-dxwtBX0023)
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    重庆长安汽车股份有限公司工程研究总院, 重庆 401120
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2种不同金属材料的力学参数

Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)

Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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