Materials Today: Proceedings 80 (2023) 272–277

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Review: Corrosion behavior of friction stir welded magnesium alloys

Rajit Kumar, R.K. Bansal, Varun Sharma ⇑, Navdeep Minhas, Ankit Thakur
Department of Industrial and Production Engineering, Dr. B.R. Ambedkar National Institute of Technology, Jalandhar, Punjab, India

a r t i c l e i n f o a b s t r a c t

Article history: Magnesium is a low structural density and high specific strength element. This one of a kind material fea-
Available online 28 January 2023 ture has prompted a growth in the usage of magnesium and its alloys in a variety of industrial, automo-
tive, aerospace, and biological applications. High reactivity of magnesium its leads to corrodes more
Keywords: quickly than other metals. It’s essential to look at the corrosion behavior of magnesium and its alloys
Magnesium alloys in their various applications. The relevance of welding magnesium metal using the Friction Stir
Corrosion resistance Welding technique and its corrosion behavior are summarized through electrochemical measurements
Friction Stir Welding
in this review paper. In an aqueous media, the corrosion behavior of Friction Stir Welded Joints is studied,
Electrochemical measurements
Polarization curve
as well as the effect of corrosion resistance of various zones of joints.
Copyright Ó 2023 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 3rd International Con-
gress on Mechanical and Systems Engineering.

1. Introduction beneficial effect on the corrosion properties. Whereas, Pardo et al.

Magnesium alloys have excellent physical and mechanical
properties, including a high strength-to-weight ratio, electromag-
netic shielding, good vibration and shock absorption, excellent
machinability, high damping capacity, good cast ability, and recy-
clability, making them one of the lightest structural materials
[123].It is predicted to be employed in the automobile industry,
electrical goods, the aerospace sector, and other light-weight engi-
neering applications as an appropriate structural material [4].
Unfortunately, low corrosion resistance is a key drawback when
it comes to using them in aqueous and atmospheric conditions.
Furthermore, magnesium (Mg) subjected to significant chemical
activity in surroundings elements, and quickly generated magne-
sium oxide layer, which are absorptive and non-protective, there-
fore limiting its widespread use[5], and shown in Table 1.
The grain size on the corrosion properties of the alloys shows
significant effect. For magnesium alloys, many studies have been
reported the microstructural behavior on the corrosion properties
[6–10] and reported that the high susceptibility of the corrosion
behavior, the application of the magnesium alloys are limited in
the areas exposed to the atmosphere [11]. Moreover, it has been
reported that the presence of aluminum in the magnesium shows
⇑ Corresponding author.
E-mail addresses: rajitk.mt.20@nitj.ac.in (R. Kumar), bansalrk@nitj.ac.in
(R.K. Bansal), sharmav@nitj.ac.in (V. Sharma), minhasnavdeep95@gmail.com
(N. Minhas), ankitt.ip.18@nitj.ac.in (A. Thakur).
[12] reported that one of the commercial alloy i.e. AZ31B, which
contains 3.01 % aluminum composition within the matrix. Also,
the corrosion rate of the magnesium alloys generally accelerated
when the ratio of contaminants presents in the matrix such as cop-
per, nickel and iron exceeded. This could be attributed to the low
solid solubility and their capability to assist as an active cathodic
site [13].
Many parameters, including grain size, dislocation density, tex-
ture, and twins, have an influence on the corrosion resistance of Mg
alloys[14–16]. Magnesium alloys have limited welded ability
owing to the creation of solidification fractures and porosities dur-
ing the melting and solidification processes[17].Therefore riveting
is preferred over welding in the aerospace industry is because of
this [1819].
A new approach to combining these alloys has arisen with the
invention of the friction stir welding (FSW) procedure[17]. FSW
looks to be a better option to traditional non-ferrous alloy welding.
Less heat is generated throughout the process, there is no porosity,
there are fewer residual strains, there is less distortion, and there
are fewer weld flaws[20–24]. FSW offers a major advantage in
the joining of Mg alloys as a solid-state welding method[16].How-
ever, since FSW is a thermo-mechanical process, the severe plastic
deformation and high temperature exposure inside the stirred
zone may result in significant microstructural changes at the
Thermo-Mechanical Affected Zone (TMAZ) and Heat Affected Zone
(HAZ) [17], such as recrystallization, precipitate dissolution in Stir-
ring Zone (SZ), and precipitate coarsening. Furthermore, these

https://doi.org/10.1016/j.matpr.2023.01.169
2214-7853/Copyright Ó 2023 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 3rd International Congress on Mechanical and Systems Engineering.
R. Kumar, R.K. Bansal, V. Sharma et al. Materials Today: Proceedings 80 (2023) 272–277

Table 1
Corrosion potential(Ecorr(volt) and current density(Icorr(A/cm2)).

No. Specimen Solution Ecorr(volt) Icorr(A/cm2) Ref

1. AZ31 BM M
1.597 1.14E-06 [42]
2. FSW M
1.580 1.52E-06 [42]
3. HAZ N
1.440 0.000282 [33]
4. TMAZ N
1.450 0.000126 [43]
5. SZ N
1.460 0.00017 [43]
6. TMAZ N
1.480 0.000151 [43]
7. HAZ N
1.460 0.000156 [43]
8. SZ N
1.494 4.78E-05 [26]
9. TMAZ N
1.471 8.29E-05 [26]
10. HAZ N
1.455 8.32E-06 [26]
11. BM N
1.411 2.75E-05 [26]
12. AZ31 SZ P
1.408 2.8E-06 [44]
13. AZ31 BM P
1.469 1.03E-05 [44]
14. AZ80 SZ P
1.499 1.1E-06 [44]
15. AZ80-BM P
1.500 2.8E-06 [44]
16. AZ31B-H24 N
1.451 – [44]
17. AZ31B-H24 N
1.471 – [44]
18. AZ31B-T4 N
1.481 – [44]
19. AZ31B-T4 N
1.416 – [44]
20. BM-6 N01 X+Y
0.890 7.3E-07 [45]
21. BM-AZ31B X+Y
1.480 2.81E-06 [45]
22. SZ X+Y
1.410 2.24E-05 [45]
23. Mg-AZ31B Q
1.650 0.05266 [46]
24. Al-AA6061 Q
0.390 7.3E-06 [46]
25. FSW Q
1.370 0.03212 [46]
26. BM R
1.610 0.000834 [47]
27. FSW R
1.450 6.21E-05 [47]
28. Processed R
1.290 1.23E-05 [47]

BM = Base Metal; M = saline water; N = 3.5 wt% NaCl; P = 0.086 M NaCl; Q = 0.5 M NaCl; R = 60 g/L NaCl; X = 0.1 M Na2SO4; Y = 0.5 M NaCl.

microstructural alterations in the welding zones may promote var-
ied and interesting anti-corrosion performance [17].
Indeed, under a broad range of pH values, the surface films that
develop spontaneously on Mg and its alloys are weakly protected
and exceedingly fragile. In the alkaline medium, the passive film
of magnesium and its alloys has efficient stability across a wide
pH range. Under certain circumstances, the passivity of the passive
layer breaks down, forming an effective barrier against metal [25].
2. Friction stir welding
The friction stir weld (FSW) is a solid state material joining
technology [26]. It was first used on aluminum alloys, resulting
in high-temperature material strain without melting the base
material[27]. Friction stir welding is accomplished by using a
non-consumable rotating tool to insert a specially designed pin
and shoulder into the invade edges of the mating plates, followed
by tool movement along the work piece’s joint line specification, as
illustrated in Fig. 1.
Friction stirring requires mechanical deformation and frictional
heating of the joining plates; this heating is produced due to fric-
tion between the plates and the shoulder of the tool. The tool
inserts into the base materials when the down force is provided
to it. A pin or probe, as well as a shoulder, make up the friction stir-
ring tool. The work piece warms up as the shoulder makes contact
with it, the softened zone expands, and the deformed material is
limited. [24 3]. Frictional and deformation heating occurs when
the pin comes into contact with the work piece, softening the
material In a friction stir applications, material qualities such as
wear resistance, coefficient of thermal expansion, enhanced tem-
perature strength, tool reactivity, fracture toughness, machinabil-
ity, and microstructure uniformity are all critical [281].
The friction stir welding (FSW) process has been effective in
providing high-quality welded connections for aluminum and
magnesium alloys, according to a substantial literature [29]. The
heat created by friction between a stirring tool and a work piece
assists in the recrystallization of metal grains, allowing them to
be cooled as a joint. [30]. Only thermal cycle variation is applied
to the base material, resulting in the development of the HAZ.
The material is exposed to a high temperature in HAZ due to heat
transferred from the SZ through TMAZ, resulting in grain coarsen-
ing [31].The geometry of the tool pin has an impact on the flow of
plasticized material and the qualities of the weld. Optimizing tool
shoulder geometry to generate more heat or accomplish more effi-
cient stirring, improves oxide layer breakdown and mixing as well
as heat generating efficiency, resulting in faster welding rates and
better weld quality [28 4].

3. Corrosion

The poor corrosion resistance of magnesium and magnesium

alloys is due to the interaction of two critical components. Magne-
Fig. 1. Friction stir welding. sium’s significant electronegativity accelerates corrosion when
273
R. Kumar, R.K. Bansal, V. Sharma et al.
oxygen is limited due to Layers created on the surface of magne-
sium welded joints have limited shielding characteristics due to
the solubility of the hydroxide layers on the surface under aqueous
conditions, the major reaction caused by cathodic water reduction
at the potential of negative charge [32].
3.1. Corrosion mechanism
The following chemical reactions describes the process of
hydro-oxidation layer creation on the surface of magnesium during
immersed in aqueous solution. MgO formed when Mg reacts spon-
taneously with oxygen at room temperature. In a dry atmosphere,
this reaction occurs in the absence of water. The extremely
exothermic character of the reaction accounts for the pyrophoric
activity of the magnesium particles [33].
1 occurs, while in alkaline and neutral media reactions (Equations
MgðsÞ þ O2 ðgÞ ! MgO ð1Þ
2 (8) and (9)) happen. Even though oxygen plays an important part
According to studies, there are three stages to the formation of
oxide layers (MgO) on the surface of Mg under humid circum-
stances [3234].
The absorption of dissociated water and the formation of a MgO
bar structure are the first two stages. In the final phase of inverse
logarithmic kinetics, a crystalline layer of MgO covers the entire
metal surface, gradually increasing in thickness [32].
Mg has a high corrosion activity in dry conditions at room tem-
perature due to the presence of MgO film. In similar situations, this
is comparable to the properties of other metals. The mechanism of
water chemisorption on magnesium oxide has been discovered to
favor the MgO surface [35].
Protolysis a chemical reaction that results in the breakdown of
water molecules, culminating and creation of H + and OH ions.
MgO surface is hydro-oxalated as a result [32].
O2
þ H2 O ðgasÞ ! 2OH
ð2Þ
Equivalently:
MgOðsurfaceÞ þ H2 O ! MgðOHÞ2 ðsurfaceÞ ð3Þ
When magnesium oxide is solid magnesium hydroxide, it reacts
with water to form brucite. This is most likely due to equilibrium
thermodynamics at lower moisture vapor concentrations.
MgOðsÞ þ H2 O ! MgðOHÞ2 ð4Þ
The layer’s lack of protection is due to the not solubility of mag-
nesium oxide and magnesium hydroxide in aqueous medium,
acidic and neutral solutions containing, as a result, the covering
generated on the surface of Magnesium fails to protect the metal
below When the hydroxide layer dissolves in the aqueous solution,
the pH of the electrolyte rises. In addition, since MgO has a greater
solubility than brucite, the surface water layer becomes supersat-
urated with Mg hydroxide [36].
The brucite precipitation occurs as a result of this. According to
studies, the layer of MgO dissolves, forming solid precipitates of
magnesium hydroxide, which is the justify the mechanism of cor-
roded specimen. Because thickness is diminishing due to the bru-
cite precipitation, the metal-fluid interaction is triggered,
exacerbating corrosion When MgO or Mg(OH)2 is immersed in liq-
uid, the quasi-passive layer dissolves (water), exposing the metal
to the liquid medium. Furthermore, secondary phases without
double layer shielding, such as noble impurities, develop when
polarized, leading in localized corrosion.
Corrosion in metals is an electrochemical process, the metal
changes its oxidized state as it shows its reactivity with its sur-
roundings. When the metal atoms, oxidize to create ionic species,
electron transfer happens at the electrode contact, releasing elec-
trons. The half-reaction for Mg oxidation (anodic) is as follows:
274
Materials Today: Proceedings 80 (2023) 272–277
Mg ! Mg2þ þ 2e
ð5Þ
To maintain electro neutrality, the free electrons must be
received by alternative groups. As a result, the oxidation process
is conducted by a cathodic (reduction) reaction; however, in acidic
and alkaline settings, the medium in which a reaction occurs has
an influence on the kind of reaction.
2Hþ þ 2e
! H2 ð6Þ
2H2 O þ 2e
! H2 þ 2OH
ð7Þ
O2 þ 2H2 O þ 4 e
! 4OH
ð8Þ
Mg þ 2H2 O ! MgðOHÞ2 þ H2 ð9Þ
when acidic environment, reactions (Equation (6) and (7))
in corrosion, these processes are unaffected by the amount of oxy-
gen dissolved in the aqueous media. The principal reduction pro-
cess for Mg exposed to the atmosphere is water reduction. This
may be seen in the responses listed above. As a result, the whole
Mg corrosion reaction is as follows.
3.2. Corrosion rate measurement
3.2.1. Immersion test
A number of approaches have been used to investigate deterio-
ration of materials are electrochemical methods and mass loss
testing (immersion test). In an immersion test there is a weight
increase if all of the corrosion products remain on the surface after
corrosion, and a weight decrease if the corrosion products are
removed that is why this is not robust, measurement the corrosion
rate [37].Immersion test are evaluated as per the standard of ASTM
G-31[38]. Experimental specimens were submerged for definite
period of time as per standard for different material and dimension
of specimen to assess the mass loss. Following the immersing test,
the samples’ initial weight (M0) and final weight (M1) were
recorded[26]. To obtain M1, corrosion products from immersed
samples were eliminated using a boiling solution of 100 g/L chro-
mic acid and 5 g/L silver nitrate (magnesium specimen). Calculat-
ing the mass loss, or M, was done using equation (10).
DM ¼ M O
M 1 ð10Þ
Generally, equation (11) is used to assess the corrosion rate of
FSW welded AZ31 in various regions.
8:76  104  DM
Corrosion rate ¼ ð11Þ
Sqt
In the immersion test AZ31B alloy has a density(q) of around
1.72 g/cm3, S is the exposed surface area of a submerged specimen
(cm2), and t is the immersion period (h).
3.2.2. Electrochemical corrosion test
Electro-chemical testing on electrochemical workstation that
are suited for field application should have two key characteristics.
First and foremost, the procedures must be dependable and easy,
which is particularly crucial for long-term corrosion monitoring.
Second, the approaches should be non-destructive in nature have
little negative influence on the materials, being studied as feasible.
Polarization curve plot gives as information about the corrosion
potential and current density of sample that is why polarization
curve are some of the most frequently utilized approaches [39].
Polarization curves of AZ91, AZ31 and pure magnesium are shown
in Fig. 2. corrosion resistance behavior shows. AZ91 > AZ31 > Pure
Mg.
R. Kumar, R.K. Bansal, V. Sharma et al.
Fig. 2. Polarization curve of AZ31,AZ91,magnesium pure(mg)[40].
For studying corrosion kinetics and processes, several modern
electrochemical techniques are useful tools. However, they may
not be suitable for field assessment since they are either too slow
in nature, consume too much time during field work, or too diffi-
cult for a normal field to use [41].
Polarization curve data shown below in table form of different
specimen.
Corrosion studies in a saline environment have indicated that
corrosion levels rise from cold to hot welds and are mostly con-
fined to the HAZ, according to F. Nascimento et al In comparison
to the base material, the optimal set of parameters resulted
increase in corrosion activity preferentially occurs near the root
of the welds [42].
F. Liu et al investigated the corrosion resistance of several loca-
tions in a friction stir welded jont and found that welded bonds
formed by the Bobbin tool outperformed the base metal by a wide
margin. The size and distribution of the precipitates, not the mean
grain size, had the greatest impact on the joint’s corrosion resis-
tance [43].
Because of its non-uniform microstructure, Y. Yao et al found
that the TMAZ has reduced corrosion resistance. Heat flow also
affects the HAZ, causing tension to be released. Despite the pres-
ence of coarse grains, the grain size distribution is quite uniform
in the HAZ. As an outcome, the HAZ has a reduced corrosion cur-
rent density, corrosion rate, and resistance value, indicating it is
far more corrosion resistant [34].
W. Aperador et al looks into the impact of grain orientation on
AZ31B corrosion resistance grain crystalline orientation has an
impact on corrosion resistance. Because of the lower surface
energy associated with their construction, closed packed basal
planes have better corrosion resistance. Because the grains on
the top surface of the SZ area were rotated during the welding pro-
cess, grain orientation was discovered to alter the corrosion behav-
ior of joints. The galvanic pair formed between the base metal and
the stir zone is found to be less than previously thought based on
cross-sectional surface investigations [44].
Heat treatment significantly decreased the dynamically recrys-
tallized grain size in friction stir welded AZ31B specimens, accord-
ing to Y. H. Jang et al. The refined grains used in the friction stir
welded AZ31B-T4 specimen may aid in the creation of a thick
and homogeneous passive coating on the surface, hence improving
corrosion resistance [45].
Y. J. Lin et al looked into the mechanism of the recrystallization
phenomenon, finding that the corrosion rate was discontinuous in
AZ31 but continuous in AM50The rotation of twin boundaries into
low and high angle boundaries as a function of deformation rate, as
275
Materials Today: Proceedings 80 (2023) 272–277
well as dislocation rearrangement into sub-grain barriers, had a
major impact on the microstructure of AZ31, resulting in grain sub-
division in AM50The slight increase in corrosion potential in the
AZ31 nugget was due solely to recrystallization, but the surface
potential in the AM50 nugget was much higher than the base
metal because both the Al-enrichment and phase dissolved into
the interior of the Mg grains in the nugget region, resulting in an
increase in Al concentration [46].
J. Verma et al claims that dissimilar friction stir weld joints
behave differently in various corrosive situations in a sulfuric
and chloride environment, with greater corrosion resistance
recorded at a high rotational speed corresponding to a low travel
speed. In comparison to rotational speed, when travel speed
increase, not shown its significant influence on microstructure,
mechanical characteristics, or corrosion resistance [47].
By incorporating Sic particles into a friction stir welded zone of
AZ31 alloy, M. Abbasi et al discovered that when an addition of
reinforced added in friction stir welded, different zones gives more
resistance to corrosion owing to the formed the oxide coating and
remove the local cell [48].
Saifiyan et al. [49] investigated the microstructural and corro-
sion behavior of the friction stir processed AZ31B alloy using mul-
tiple corrosion techniques such as potentiodynamic polarization,
electrochemical impedance spectroscopy and immersion test at
3.5 % Nacl solution. They reported that the microstructural grain
refinement due to the friction stir processing led to an improve-
ment in the corrosion resistance.
Kannan et al. [50] studied the stress corrosion cracking (SCC)
behavior through electrochemical impedance spectroscopy (EIS)
and salt spray test on the FSW joints of AZ31B and base material.
They reported that the stir zone of the welded joint exhibits
behaves better and uniform pitting corrosion resistance as com-
pare to the base material. Whereas, siakrishana et al. [51] investi-
gated the grain size on the corrosion behaviour of the FSW AZ31B
magnesium alloy on the corrosion behaviour through immersion
and electrochemical and reported that the bimodal grain distribu-
tion and textural inconsistency increased the corrosion rate.
4. Conclusions
The present paper reviewed the summaries of the the corrosion
behavior of friction stir welding joints of the magnesium alloys.
The major conclusion was as follows.
 The friction stir welding refines the grain structure of the
welded joint and also affects the corrosion behavior of the cor-
rosion behavior.
 The corrosion behavior of the different friction stir welding
zones i.e., stir zone, TMAZ/HAZ and HAZ varies with respect to
the heat input and grain refinement within the respective zone.
The stir zone has higher corrosion resistance than the other
zones.
 It is found that the texture, formation of bimodal grains, orien-
tation and formation of IMC due to the recrystallization of the
material affects the corrosion resistance
 The inclusion introduced within the stir zone such as silicon
carbide improves the corrosion resistance of the FSW joints.
CRediT authorship contribution statement
Rajit Kumar: Conceptualization, Methodology, Data curation,
Writing – original draft, Writing – review & editing, Visualization.
R.K. Bansal: Writing – review & editing, Supervision. Varun
Sharma: Conceptualization, Methodology, Resources, Investiga-
tion, Visualization, Writing – review & editing, Supervision. Nav-
R. Kumar, R.K. Bansal, V. Sharma et al.
deep Minhas: Data curation, Writing – review & editing. Ankit
Thakur: Writing – review & editing.
Data availability
Data will be made available on request.
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
Acknowledgements
The authors would like to express their gratitude for support
received from Department of Mechanical Engineering (Dr. B.R.
Ambedkar National Institute of Technology, Jalandhar) for mechan-
ical testing.
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