Corrosion of aluminium in contact with cutting fluids / electrochemistry of corrosion

Abstract

The work in this thesis concerns the behaviour of cutting fluids used for drilling aluminium. A cutting fluid which is useful must neither corrode nor stain aluminum unduly. The compositional factors which lead to a successful cutting fluid have been investigated using electrochenucal techniques. Linear sweep and impedance measurements were used to assess the corrosion of pure alummium and aluminium alloys in contact with aqueous solutions in the pH range 8-11 , in the presence and absence of oxygen. It was found that a low corrosion rate required that the solution pH was kept lower than 9.5. Clear and stable cutting fluids were formulated with and without the use of amines and the corrosion of aluminium in contact with these cutting fluid emulsions was studied. The corrosion rate of aluminium was found to be a factor of ten times lower when in contact with a typical emulsion compared to contact with an aqueous borax solution of the same pH. The most important factor in respect of corrosion control was the pH. The presence/absence of amines did not significantly affect the corrosion rates. In order to simulate the drilling process,a glass cell was designed with a glass frit situated at the base onto which an aluminium rotating disc electrode was lowered, and electrochemical measurements were made, in situ in this way. Abrasion of the electrode caused the anodic process on the metal to be affected to a greater extent than the cathodic process. The electrochemical techniques used in this work have readily allowed us to assess the suitability of different cutting fluid formulations.