The Corrosion Susceptibility of AA7050 Repaired for Aerospace Applications Via Additive Friction Stir Deposition

The purpose of this dissertation is to explore the viability of Additive Friction StirDeposition (AFSD) as a method for the repair of 7XXX-series aluminum alloy aerospace parts byexamining the corrosion response of materials processed with this technique. To date, the majorityof studies involving AFSD have pertained to mechanical and/or microstructural properties ofmaterial produced via AFSD. This leaves a gap in scientific knowledge revolving around thecorrosion susceptibility of these materials. This dissertation contains a combination ofelectrochemical, gravimetric, exposure, and microscopy techniques that were leveraged tounderstand the mechanisms involved in the corrosion of these materials. Key findings include theanodic behavior of as-deposited material produced via AFSD relative to the wrought substratematerial, differences in corrosion response based on height within large-scale builds due to forcedaging from latent and residual heat, better corrosion response for corroded materials that have beenrepaired via AFSD without the removal of corrosion product prior to repair (in the as-depositedstate), and an increase in the efficacy of corrosion-inhibiting surface treatments for as-depositedmaterials produced via AFSD when compared to those applied to wrought substrate. Thesefindings show that AFSD may provide a viable solution for the production and/or repair ofaerospace components, with the understanding that additional heat treatments and corrosion-inhibitingsurface treatments will likely be required for long-term repairs.

Grantor dc:publisher

University of Alabama Libraries

Year dc:date.issued

2026

Author dc:creator

• Geisler, Justin Blake

Advisor dc:contributor.advisor

• Kubacki, Gregory W.

Contributors dc:contributor

• Kasemer, Matthew
• Kumar, Nilesh
• Zhang, Qiaofu
• Schneider, Judy

• Additive Friction Stir Deposition
• Aluminium Alloys
• Aluminum Alloys
• Corrosion
• Intergranular Corrosion
• Precipitates

Statement dc:rights

• All rights reserved by the author unless otherwise indicated.

Language dc:language.iso

en_US, English

Dc Identifier Other

1217136

OAI identifier oai:identifier

oai:ir.ua.edu:123456789/17969