This study investigated the effect of post-brazing cooling rate and Si addition on the intergranular corrosion (IGC) susceptibility of brazed Al-Mn-Cu alloys by electrochemical analysis and microstructure observation. Water-quenched samples after brazing exhibited no IGC susceptibility, whereas slowly-cooled samples were prone to IGC. The results suggest that IGC is caused by precipitation during cooling. In addition, it was observed that IGC susceptibility depended on the Si content. An alloy sample with a low Si-additive content exhibited high IGC susceptibility because Mn/Cu-depleted zone was formed near the grain boundaries as a result of the preferential precipitation of Al 6 (Mn,Fe) and CuAl 2 on the grain boundaries. In contrast, moderate Si addition inhibited IGC because the decrease of the Mn content in the grain interiors due to enhanced precipitation of Al 15 (Mn,Fe) 3 Si 2 in the grain. Additionally, Cu-depleted zone also disappeared because preferential precipitation of CuAl 2 on the grain boundaries was prevented. The excess-Si alloy exhibited high IGC susceptibility because Si-depleted zone formed around the grain boundaries as a result of the preferential precipitation of coarse Si particles on the grain boundaries although the Mn/Cu-depleted zones were not formed.

Al-Mn based alloys with high-manganese content are expected to have improved mechanical properties due to solid solution hardening and/or dispersion hardening. However, the increase of Mn solubility of the alloy is difficult by using the conventional DC casting. In order to solve this problem, in the present study, we focused on the twin-roll casting method which is characterized by high cooling rates. Several kinds of high Mn-containing Al-Mn-Si alloy strips were fabricated by using a vertical-type high-speed twin-roll caster equipped with a pair of water-cooled copper rolls. Direct temperature measurement of the liquid melt during the casting was also performed. The alloy strips of various compositions containing up to 4 Mn and 2 Si (wt%) were successfully obtained. By observing the microstructure of the cross section of the strip, we found the characteristic solidified structure. The solidified structure consisted of three layers. Two solidified shells with a columnar dendrite structure grew from the roll surfaces toward the strip center. In the mid-thickness region, the band structure consisting of equiaxed dendrites and globular grains was observed between the solidified shells. Very fine primary particles were observed in the matrix near the strip surface, while, relatively coarse particles with blocky and needle-like shape were observed in the central band of the as-cast strip. The electric conductivity measurement was performed for the as-cast strips. Mn solubility in Al matrix was estimated from the obtained values. The estimated Mn solubility in the Al-2Mn-xSi strips was between 1.5 ~ 1.8wt% Mn. It was over 1.43wt%Mn for the Al-4Mn-xSi strips. We found that the Mn solubility of the as-cast strips was considerably high. The strips were cold-rolled to the sheets and then annealed at various conditions. They were subjected to the tensile tests, and the effects of solid solution hardening and dispersion hardening are discussed.

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This paper investigated the effect of Si addition on intergranular corrosion susceptibility for brazed Al–Mn–Cu alloy. Water-quenched samples have no intergranular corrosion (IGC) susceptibility, however, slowly cooled samples have IGC susceptibility. This implies that IGC susceptibility was caused by precipitation during cooling. In addition, IGC susceptibility depends on Si content. Low Si additive alloy has high IGC susceptibility. This is because the Mn/Cu depleted zone is formed near the grain boundary due to preferential precipitation of Mn-bearing compound and CuAl2 on the grain boundary. Conversely, optimum Si addition inhibits IGC due to the absence of preferential precipitation on the grain boundary. The excess Si alloy has high IGC susceptibility as the Si depleted zone is formed around the grain boundary due to the preferential precipitation of coarse Si particles on the grain boundary.

To investigate the effects of Si and Cu on strength and corrosion rate of sacrificial anode fin stock of Al-1.5%Mn-0.2%Fe-1.5%Zn alloy for automotive heat exchangers, tensile test and SWAAT have been carried out. Strength increased with Si and Cu addition. Corrosion rate did not increase with Si addition in spite of increase of a-AlMnSi compound density, because the compounds did not work as effective cathode in the alloy. On the other hand, corrosion rate increased with Cu addition. This was explained in the existence of deposited Cu on the specimen surface during SWAAT worked as strong cathode in the alloy. Cathodic polarization characteristics in 3.5% NaCl solution rather than in SWAAT solution were effective to evaluate corrosion rate of the alloys in SWAAT.