Size‐Dependent Corrosion of Al‐Fe Intermetallic Particles at Al‐Mg Alloy Surfaces Investigated by In‐Liquid Nanoscale Potential Measurement Technique

Abstract Corrosion of Al alloy often starts from the nanoscale corrosion around the surface‐exposed Al‐Fe intermetallic particles (IMPs) and leads to a serious damage limiting its application range in the automobile industry. To solve this issue, understanding of the nanoscale corrosion mechanism around the IMP is essential, yet it is impeded by the difficulties in directly visualizing nanoscale distribution of reaction activity. Here, this difficulty is overcomed by open‐loop electric potential microscopy (OL‐EPM) and investigate nanoscale corrosion behavior around the IMPs in H₂SO₄ solution. The OL‐EPM results reveal that the corrosion around a small IMP settles down in a short time (<30 min) after transient dissolution of the IMP surface while that around a large IMP lasts for a long time especially at its edges and results in a severe damage of the IMP and matrix. This result suggests that an Al alloy with many small IMPs gives a better corrosion resistance than that with few large IMPs if the total Fe content is the same. This difference is confirmed by corrosion weight loss test using Al alloys with different IMP sizes. This finding should give an important guideline to improve the corrosion resistance of Al alloy.