SYNOPSIS The study investigates the effect of prior corrosive exposure on crack growth resistance behaviour of thin sheet (3 mm thick) aluminium alloy 2024-T3 at slow strain rates. Compact tension specimens were exposed to standard corrosive environments that simulate accelerated atmospheric corrosion attack. TWo corrosive environments were considered - an exfoliation corrosion (EXCO) solution and a 3.5 wt% sodium chloride solution. The unloading compliance R-curves of the two-hour EXCO-exposed specimens revealed a significant degradation of approximately 11% in the crack growth resistance behaviour (Kcevalues) compared to the baseline (air-exposed) values. Furthermore, secondary intergranular crack formation was also revealed in the plastic zone ahead of, and adjacent to, the crack tip of these specimens; which formed during the crack growth resistance loading. It is postulated that the observed degradation of the Kce values of the EXCO-exposed material is due to hydrogen embrittlement since the exposure times for the EXCO evaluation were limited to ensure that uniform corrosion dominated; that is, significant penetration of corrosion damage and pitting due to localized corrosive attack did not occur. The sodium chloride-exposed specimens revealed a similar degradation (13%) after 24 hours exposure. However, slight intergranular corrosive attack and isolated pitting were observed on the exposed surfaces prior to crack growth resistance loading, resulting in notch effects that could assist in crack growth. Pitting and intergranular corrosion were, however, not observed at the pre-crack tip. The relative contributions of the notch effects and the hydrogen embrittlement during the degradation of the KR performance are, therefore, unclear. Keywords: corrosion, crack growth, aluminium alloy 2024-T3.

Aluminium alloy 2024-T3 was examined – using a range of microscopy techniques – at the early stages of corrosion attack to investigate the corrosion-induced cracking mechanism. Two different corrosive environments, exfoliation corrosion (EXCO) and 3.5 % wt. NaCl, were used for the exposure of tensile and pre-notched compact-tension C(T) specimens of AA2024-T3. Different embrittlement mechanisms are noticed for the two investigated corrosive environments. Significant intergranular corrosion (IGC) and grain boundary embrittlement is evident in the specimens exposed to EXCO solution, while this was not the case for the milder solution; comprising of 3.5 % wt. NaCl. With regards to the milder solution, corrosion attack is not restricted to the grain boundary, but evolves transgranularly to the neighbouring grains of the IGC attacked region and, consequently, the grain boundary strength in the direct vicinity is not notably affected. The extent of secondary cracks – after the exposure of C(T) specimens to EXCO solution and the subsequent crack-growth resistance evaluation – were found to correlate with the diameter of the plastically affected zone (≈ 3.78 ± 0.04 mm). Additionally, the depth of these cracks was found to correlate well with the thickness of the intergranular fracture surface, giving evidence that the secondary cracks form due to grain boundary embrittlement; probably attributed to hydrogen embrittlement phenomena.