Electrochemical corrosion behavior of 7075 aluminum alloy with different ultrasonic surface rolling microstructures

7075 Al alloy is strengthened by ultrasonic surface rolling process (USRP), and the process parameters are changed to regulate the microstructure. The thickness, grain size and distribution of different strengthening layer are characterized in detail by scanning electron microscopy (SEM) and transmission electron microscopy (TEM). The influence of different strengthening structures on their electrochemical corrosion behavior are studied using scanning Kelvin probe (SKP) and electrochemical impedance spectroscopy (EIS). The results show that the average grain size of untreated Al alloy is 2.89 μm, the surface SKP potential is low and fluctuates greatly, and has high sensitivity to pitting corrosion. After USRP treatment, the surface roughness of 7075 Al alloy decreases, the grain size is significantly refined and shows a gradient distribution, SKP potential in the strengthening area increases and becomes more stable, the passive film on the surface thickens, the density of pits significantly decreases, and the corrosion resistance is improved. Besides, the samples with thicker plastic deformation layer and surface nanocrystallization (average size of 39.9 nm) exhibit better performance compared to other samples.