10.1115/IMECE2025-166707">
 

Superhydrophobic Coatings for the Corrosion Preventions of Dissimilar and Similar Friction Stir Spot-Weld Joint Aerospace Alloys

Document Type

Conference Proceeding

Publication Date

11-16-2025

Abstract

Friction stir spot welding (FSSW) is a solid-state welding technique capable of joining the materials with wide variations in their properties. FSSW could replace rivet joints but this type of welding results in a loss of corrosion resistance in the weld. There is a growing need toward utilizing lightweight components and structures in the transportation industry to save energy and money and minimize environmental impact. This research investigates the effect of a superhydrophobic coating on the galvanic corrosion mechanism in the FSSW. In this study, FSSW was performed on two samples i.e. AA2024-T3 and AA7075-T6 and superhydrophobic coating with micro-nanostructure was done on these samples to minimize the detrimental effects of corrosion. The coating was composed of 58.7 wt.% mineral spirits, 12.8 wt.% silicone (Si) component, 17.8 wt.% 74 μm aluminum (Al) particles, and 10.7wt % < 45 nm zinc oxide (ZnO) particles. Superhydrophobicity of the coatings was determined by measuring static water contact angle (WCA) and it was determined that the WCA was 158°. Adhesion of the coating to the substrate was verified by cross-hatch tape testing according to ASTM D3359, which showed less than 5% loss of material. Durability of the coating was tested by exposing crosshatch solution with a pH of 9, a 0.5M H2SO4 acid solution, and an acetone solvent. Corrosion mitigation of the coating was determined by comparing electrochemical testing of the coated AA2024 specimens, coated AA7075 specimens, and coated friction stir spot welds, with uncoated FSSW and bare aluminum materials. It was demonstrated that coating improved corrosion mitigation by lowering the current density with a more positive potential. Compared to the bare materials, the coated specimens’ corrosion rates were noticeably lower. Abstract Copyright © 2025 by ASME and The United States Government.

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Source Publication

ASME 2025 International Mechanical Engineering Congress and Exposition, Volume 3: Advanced Materials: Design, Processing, Characterization and Applications; Advancements in Industry; Advances in Aerospace Technology (ISBN 9780791889343)

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