Study on the Corrosion Behavior of Al-Li Alloy in Simulated Propellant Environments

Mengqing Liu; Fei Hu; Yi Wu; Wei Zhao

doi:10.6919/ICJE.202508_11(8).0025

Authors

Mengqing Liu
Fei Hu
Yi Wu
Wei Zhao

DOI:

https://doi.org/10.6919/ICJE.202508_11(8).0025

Keywords:

Aluminum-Lithium Alloy; Corrosion Mechanism; Propellant; Corrosion Fatigue.

Abstract

Liquid-fueled strategic missiles are a core component of China’s strategic deterrence force, offering excellent payload capacity and long-range strike capabilities. They serve as a key element in both nuclear deterrence and nuclear counterstrike operations. However, due to the large scale and complex structure of liquid missile systems, as well as their relatively long operational preparation cycles, the rapid generation of combat readiness presents a significant challenge. To enhance the operational effectiveness of liquid-fueled strategic missiles, this paper systematically investigates the corrosion mechanisms of aluminum-lithium (Al-Li) alloys in acidic environments. A continuum damage model was established to simulate the full corrosion fatigue damage evolution process-from localized damage to failure. Scanning electron microscopy (SEM) was used to analyze the corrosion morphology and corrosion products of Al-Cu alloys, revealing that the formation of pre-precipitated phases at grain boundaries significantly affects corrosion behavior. Synchrotron radiation X-ray tomography was employed to observe the intergranular corrosion morphology of aluminum alloys, revealing a fine network-like corrosion pattern. Furthermore, the role of intermetallic particles (IMPs) in localized corrosion was investigated, indicating that high-copper-content IMPs are more electrochemically active and more prone to initiating corrosion. These findings provide critical theoretical and technical support for improving the reliability and service life of liquid-fueled strategic missiles.

Downloads

Download data is not yet available.

References

[1] Zhang Lingquan.Current status of aluminum-lithium alloys[J].Light Alloys Fabrication Technol.1986(7): 23-28.

[2] Xia Deshun.Development and application of aluminum-lithium al-loys[J].Astronavigation Craft.1998(1): 50-54

[3] Qiu Huizhong.Al-Li alloys and their manufacturing techniques for aerospace products outside China[J].Aerospace Mater.Technol.1998(4): 39-43

[4] Tian Rongzhang Wang Zhutang.Aluminum Alloys and Their Fabri-cation[M].Changsha: Central South University Publication Press 2000.

[5] Liu Jing’an Zhu Xianwen.Development and application of alu-minum- lithium alloys[J].Light Alloy Fabrication Technol.199624(5): 2-5--10

[6] Colvin E L Cahhen G LStoner G E.Effect of germanium additions on the corrosion behavior of an Al-Li alloy[J].Corrosion 1986 42(7): 416-421

[7] Niskanen P Sanders T H Rinker J G et al.Corrosion of aluminum alloys containing lithium[J].Corros.Sci.1982 22(4): 283-304

[8] Moran J PStarke E A Stoner G E et al.The influence of composi-tion and microstructure on the corrosion behavior of two AlLiX al-loys[J].Corrosion 1987 43(6): 374-382

[9] Buchheit R G, HLAVA P F, MCKENZIE B, et al. Local dissolution phenomena associated with S phase (Al2CuMg) particles in aluminum alloy 2024-T3 [J]. Journal of the Electrochemical Society, 1997, 144(8): 2621-2628.

[10] Buchheit R G Moran J P Stoner G E.Localized corrosion behavior of alloy2090-the role of microstructure heterogeneity[J].Corro-sion 1990 46(8): 610-617

[11] Kumai C Kusinski J Thomas G et al.Influence of aging at200℃on the corrosion resistance of Al-Li and Al-Cu-Li alloys[J].Corrosion 1989 45(4): 294-302

[12] Ambat R Dwarakadasa E S.Effect of chloride ion concentration during corrosion of medium strength aluminum alloys8090 2091 and2014[J].Br.Corros.J. 1993 28(2): 142-148

[13] Ambat R Dwarakadasa E S.The influence of pH on the corrosion of medium strength aerospace alloys8090 2091and2014 [J].Cor-ros.Sci.1992 32(5): 681-690

[14] Pang, C., Liu, D. J., Tian, G., et al. (2024). Experimental and simulation study on fatigue multi-crack coalescence in 2195-T8 Al-Li alloy. Journal of Beijing University of Aeronautics and Astronautics, 50(01), 350–358.

[15] Guo, Y., Tian, G., Liu, D. J., et al. (2022). Corrosion behavior of Al-Li alloy in acidic environments and its cellular automata simulation. China Mechanical Engineering, 33(08), 1001–1007.

[16] Guo, Y., Chang, X. L., Tian, G., et al. (2022). Pre-corrosion fatigue behavior of 2195-T8 Al-Li alloy in N₂O₄ under tension-tension loading. Rare Metal Materials and Engineering, 51(09), 3459–3465.

[17] Guo, Y., Liu, D. J., Chang, X. L., et al. (2024). Corrosion behavior of 2195-T8 Al-Li alloy with artificial defects in 30% HNO₃. Journal of Beijing University of Aeronautics and Astronautics, 50(03), 896–903.

[18] Liu, D. J., Tian, G., Li, Y. L., et al. (in press). (2024) Research on the pre-corrosion fatigue properties of 2195 Al-Li alloy in 30% HNO₃. Journal of Beijing University of Aeronautics and Astronautics.50,1129-1137

[19] Liu, D. J. (2023). Study on the evolution of stress corrosion damage of Al-Li alloy for new liquid propellant tanks under long-term wet storage conditions (Master’s thesis). Rocket Force University of Engineering, Xi’an, China.

[20] Guo, Y. (2024). Study on stress corrosion and fatigue properties of 2195 Al-Li alloy in N₂O₄ environment (Master’s thesis). Rocket Force University of Engineering, Xi’an, China.

[21] Kong, M., Wu, J. J., Han, T. R., et al. (2020). First-principles study on the corrosion mechanism of the T1 phase in Al-Cu-Li alloys. Acta Physica Sinica, 69(2), 208–215.

[22] Zhang X X, Zhou X R, Hashimoto T, et al. Corrosion behavior of 2A97-T6 Al-Cu-Li alloy: The influence of non-uniform precipitation[J]. Corrosion Science, 2018, 132(3): 1-8.

[23] Grill R, Mark A B, Castle J E, et al. Localized corrosion of a 2219 aluminum alloy exposed to a 3.5% NaCl solution[J]. Corrosion Science, 2010, 52: 2855-2866.

[24] Charalampidou C, Dietzel W, Zheludkevich M, et al. Corrosion-induced mechanical properties degradation of Al-Cu-Li aluminium alloy and the role of side-surface cracks[J]. Corrosion Science,2021, 10.1016/j.corsci.2021.109330.

[25] Moreto J A, Broday E E, Rossino L S, et al. Effect of localized corrosion on Fatigue-Crack Growth in 2524-T3 and 2198-T851 aluminum alloy alloys used as aircraft materials[J]. Journal of Materials Engineering and Performance, 2018, 27, 1917-1926.

[26] Moreto J A, Marino C E B, Filho W W B, et al. SVET, SKP and EIS study of the corrosion behavior of high strength Al and Al-Li alloys used in aircraft fabrication[J], Corrosion Science, 2014, 84(7): 30-41.

[27] Geobel J, Ghidini T, A J G. Stress-Corrosion Cracking Characterisation of the Advanced Aerospace Al-Li 2099-T86 Alloy[J]. Materials Science and Engineering, 2016, 673:16-23.

[28] Araujo J V, Milagre M X, et al. Exfoliation and intergranular corrosion resistance of the 2198 Al-Cu-Li alloy with different thermomechanical treatments[J]. Materials and Corrosion, 2020, 1-14.

[29] Boag A, Hughes A E, Glenn A M, et al. Corrosion of AA2024-T3 Part I: Localized corrosion of isolated IM particles[J]. Corrosion Science, 2011, 53, 17-26.

[30] Boag A, Taylor R J, Muster T H, et al. Stable pit formation on AA2024-T3 in a NaCl environment[J]. Corrosion Science, 2010, 52, 90-103.

[31] Luo C, Albu S P, Zhou X, et al. Continuous and Discontinuous Localized Corrosion of a 2xxx Alumnium-copper lithium Alloy in Sodium Chloride Solution[J]. Journal of Alloys and Compounds, 2016, 2(658): 61-70.

[32] Rao, S. X., Zhu, L. Q., Li, D., et al. (2007). Influence of mechanochemical effects on the pitting behavior of LY12CZ aluminum alloy. Journal of Chinese Society for Corrosion and Protection, 27(04), 228–232.

[33] Chen G S, Wan K C, Gao M, et al. Transition from pitting to fatigue crack growth-modeling of corrosion fatigue crack nucleation in a 2024-T3 aluminum alloy[J]. Materials Science & Engineering A. 1996, 219(1):126-132.

[34] Wang H, Han E. Simulation of metastable corrosion pit development under mechanical stress[J]. Electrochimica Acta. 2013, 90:128-134.

[35] Ishihara S, Nan Z, Mcevily A, et al. On the initiation and growth behavior of corrosion pits during corrosion fatigue process of industrial pure aluminum[J]. International Journal of Fatigue. 2008, 30(9):1659-1668.

[36] Duquesnay D. Fatigue crack growth from corrosion damage in 7075-T6511 aluminium alloy under aircraft loading[J]. International Journal of Fatigue. 2003, 25(5):371-377.

[37] Xu L Y, Cheng Y F. Development of a finite element model for simulation and prediction of mechanoelectrochemical effect of pipeline corrosion[J]. Corrosion Science. 2013, 73: 150-160.

[38] Gamboa E, Linton V, Law M. Fatigue of stress corrosion cracks in X65 pipeline steels[J]. International Journal of Fatigue. 2008, 30(5): 850-860.

[39] Turnbull A, Horner D A, Connolly B J. Challenges in modelling the evolution of stress corrosion cracks from pits[J]. Engineering Fracture Mechanics. 2009, 76(5): 633-640.

[40] Sabelkin V, Perel V Y, Misak H E, et al. Investigation into crack initiation from corrosion pit in 7075-T6 under ambient laboratory and saltwater environments[J]. Engineering Fracture Mechanics. 2015, 134: 111-123.

[41] Kovalov D, Fekete B, Engelhardt G R, et al. Prediction of corrosion fatigue crack growth rate in alloys. Part I: General corrosion fatigue model for aero-space aluminum alloys[J]. Corrosion Science. 2018, 141: 22-29.

[42] Wang X, Wang J, Yue X, et al. Effect of aging treatment on the exfoliation corrosion and stress corrosion cracking behaviors of 2195 Al–Li alloy[J]. Materials & Design. 2015, 67: 596-605.

[43] Song H, Liu C, Zhang H, et al. In-situ SEM study of fatigue micro-crack initiation and propagation behavior in pre-corroded AA7075-T7651[J]. International Journal of Fatigue. 2020, 137: 105655.

[44] Sun B. A continuum model for damage evolution simulation of the high strength bridge wires due to corrosion fatigue[J]. Journal of Constructional Steel Research. 2018, 146: 76-83.

[45] Huang L, Chen K, Li S. Influence of grain-boundary pre-precipitation and corrosion characteristics of inter-granular phases on corrosion behaviors of an Al–Zn–Mg–Cu alloy[J]. Materials Science and Engineering: B. 2012, 177(11): 862-868.

[46] Sun B, Li Z. A Micro-Mechanism-Based Continuum Corrosion Fatigue Damage Model for Steels[J]. Journal of Materials Engineering and Performance. 2018, 27(5): 2586-2594.

[47] Knight S P, Salagaras M, Wythe A M, et al. In situ X-ray tomography of intergranular corrosion of 2024 and 7050 aluminium alloys[J]. Corrosion Science. 2010, 52(12): 3855-3860.

[48] Ma Y,Zhou X, Huang W, et al. Localized corrosion in AA2099-T83 aluminum–lithium alloy: The role of intermetallic particles[J]. Materials Chemistry and Physics. 2015, 161: 201-210.

[49] Ma Y, Zhou X, Meng X, et al. Influence of thermomechanical treatments on localized corrosion susceptibility and propagation mechanism of AA2099 Al–Li alloy[J].Transactions of Nonferrous Metals Society of China. 2016, 26(6): 1472-1481.

[50] Zheng, Z. Q., Chen, Y. Y., Zhong, L. P., et al. (2010). Initiation and propagation behavior of fatigue cracks in 2524-T34 alloy. The Chinese Journal of Nonferrous Metals, 20(01), 37–42.

[51] Pidaparti, R. M., & Patel, R. K. (2010). Investigation of a single pit/defect evolution during the corrosion process. Corrosion Science, 52(9), 3150–3153.

[52] Godard. (1987). Microstructure and stress corrosion cracking relationship in an Al-Li-Cu-Zr alloy. Materials Science and Engineering, 93, 235–245.

[53] Chen, M. C., Wen, Q. Q., et al. (2010). Initiation and propagation behavior of fatigue cracks in 2524-T34 alloy. The Chinese Journal of Nonferrous Metals, 20(01), 37–42.

[54] Li, L., et al. (2020). First-principles study on the corrosion mechanism of the T1 phase in Al-Cu-Li alloys. Acta Physica Sinica, 69(2), 208–215.

[55] Zhang, E. S., Guo, D. X., Wang, Y. C., et al. (2014). Study on mechanical property degradation of aluminum alloys in corrosive environments. Ordnance Material Science and Engineering, (5), 23–27.

[56] Liu, Y. Q., & Liu, J. (2012). Cellular automata simulation of pitting corrosion on tank bottom plates. Chemical Machinery, (4), 487–490. ISSN 0254-6094.

[57] Wang, H., Lü, G. Z., Wang, L., & Zhang, Y. H. (2008). Cellular automata simulation of corrosion damage evolution on metal surfaces. Acta Aeronautica et Astronautica Sinica, 29(6), 1490–1496. ISSN 1000-6893.

[58] Meletis E I.Microstructure and stress corrosion cracking relation-ship in an Al-Li-Cu-Zr alloy[J].Mater.Sci.Eng.1987 93:235-245

[59] Lumsden J B Allen A T.The stress corrosion cracking of Al Li al-loy8090[J].Corros.Sci.1988 44(4):527-532

[60] Dorward R C.Influence of grain structure on stress corrosion cracking and tensile properties of Al-2Li-2Cu-1.5Mg alloy sheet[J].Corrosion 1990 46(4):348-352

[61] Buis A Schijve J.Stress corrosion cracking behavior of Al-Li 2090-T83alloy in artificial seawater[J].Corrosion 1992 48(11): 898-909

[62] Conde A Fernandez B J Damborenea J J de.Characterization of the SCC behavior of 8090Al-Li alloy by means of the slow-strain-rate technique[J].Corros.Sci.1998 40(1):91-102

[63] Li Di Zuo ShangzhiGuo Baolan.Study on the exfoliation corrosion of LY 12alloy[J].J.Chin.Soc.Corros.Prot. 1995 15(3):203-208

[64] Zheng Ziqiao.Processing of the2nd National Aluminum-Lithium alloys [C].Changsha: Central South University of Technology Pub-lication Press, 1993