Effect of corrosion behavior of cast and extruded ZK60 magnesium alloys processed via friction extrusion

• Enhanced corrosion resistance in ShAPE-processed ZK60 alloys. • Microstructural refinement leads to uniform solute distribution. • Distinctive grain boundary corrosion patterns observed. • Reduced disparity in pitting potential between cast and extruded samples. The increasing demand for high-strength, corrosion-resistant magnesium alloys in transportation has led to the development of new processing techniques. In this work, cast and extruded ZK60 magnesium alloys were processed using the innovative solid-phase process, Friction Extrusion (FE). The microstructure was analyzed using Scanning Electron Microscopy (SEM), and Energy Dispersive Spectroscopy (EDS), showing a marked reduction in grain size, uniform solute distribution (Zn and Zr), and second phases after FE processing. Moreover, optical micrographs and Electron Backscatter Diffraction (EBSD) were employed to further evaluate the alloy microstructure. The corrosion resistance and electrochemical behavior were analyzed using potentiodynamic polarization, Scanning Electrochemical Cell Impedance Microscopy (SECCIM), and atomic emission spectroelectrochemistry analysis (AESEC). Time evolution surface imaging and post-corrosion microstructures were also analyzed to support the understanding of underlying corrosion mechanisms. Corrosion initiation and propagation in FE-processed samples followed grain boundary patterns, differing from cast and extruded ZK60 behaviors. Electrochemical measurements and in-situ time-dependent optical imaging demonstrated that FE processing enhanced corrosion potential, reduced corrosion current, and increased cathodic activity. Additionally, FE processing reduced the disparity in pitting potential between cast and extruded samples, resulting in intermediate pitting potentials. Higher Mg and lower Zn dissolution was observed in the lower anodic currents for FE-processed samples. During aggravated anodic current cycles, Mg dissolution equalized, but the Zn/Mg dissolution ratio increased for FE-processed extruded samples, suggesting less cathodic activation and better resistance to further pitting.