The highly deformed, micrograined layer on the outermost surface of a rolled Al-Fe-Si-Mn model alloy was electrochemically characterized. The thickness of this deformed surface layer in a 1.0 mm thick sheet was approximately 1 m. Polarization curves in 5% NaCl solution at pH 3.0 and 11.5 were obtained at different depths from the surface using controlled sputtering in a glow discharge optical emission spectrometer for sample preparation. Both the anodic and the cathodic reactivity of the deformed surface layer were significantly higher than that of the bulk. Consistent with this, image analysis of scanning electron microscopy backscattered images revealed an increased number of fine intermetallic particles in the surface layer as compared with the bulk of the material. The corrosion morphology of the outermost surface was characterized by a high density of fine pits, while fewer and larger pits were observed in the bulk. The results highlight the importance of heavily deformed surface layers in controlling corrosion behavior of rolled aluminum products.During the production of aluminum sheet, the surface of the material receives different thermomechanical treatment from the bulk. As a result of friction between the sheet surface and the work rolls during rolling, the outermost layer of aluminum metal is subjected to significantly higher levels of strain than the underlying bulk material. This enhanced shear deformation of the surface results in a very different microstructure compared with the bulk. 1-3 The surface layer is characterized by a very fine, submicrometer grain size and contains incorporated second phase particles, primarily oxides, which prevent recrystallization. During subsequent heattreatment, precipitation of fine intermetallic phases can occur preferentially in the surface layer, resulting in a higher dispersoid density and lower solute levels than bulk. 4,5 Fine intermetallic phases are also formed at the surface by fragmentation of the particles already present at the surface.Afseth et al. 6-10 have found a strong correlation between the presence of deformed layers and filiform corrosion susceptibility of 3xxx and 5xxx series aluminum alloys. The hot-rolled material is more susceptible to filiform attack than the cold-rolled material, and the susceptibility increases further with heat-treatment. 8 The microstructure of the materials reveals the presence of fine intermetallic phases within the thin deformed layer, although the investigation could not establish significant change in solid solution Mn content at the surface. 9 Removal of the active surface layer by caustic etching improved the filiform susceptibility of the material. 8 Etching also removed the substrate sensitivity to heat-treatment, indicating that the enhanced precipitation is associated with the deformed layer. By cold-rolling a corrosion-resistant etched sample, the sensitivity to filiform attack after heat-treatment can be reintroduced. 8 The effect is associated with the precipitation of intemetallic particles during thermo...