3rd ISSE National Conference on Complex Engineering Systems of National
Importance:Current Trends & Future Perspective (INAC-03), October 12-13, 2017
AM-0017 Corrosion Protection of Weldable AA2219
alloy Review & Case Study
Swarupendra Bhattacharyya1, a, Pravin Roy1, b, T.K.B. Kumaresh Babu1, c and Satish Chandra Kumar1, d*
a
swarupendra@lpscb.dos.gov.in, bpravin_r@lpscb.dos.gov.in, ctkbkbabu@lpscb.gov.in, dsatishck@lpscb.dos.gov.in.
*corresponding author
1
Liquid Propulsion Systems Centre, ISRO, Bangalore, India
AbstractThestudy describes the corrosion protection
of AA2219 alloys prior to welding of components for
aerospace manufacturing applications. Different studies
conducted for protection of AA2219 alloy is discussed
briefly, thereby identifying the most suitable method
with utmost effectiveness. The process elucidates the
anodisation of components with sulphuric acid for long
term storage with subsequent scrapping / De-
anodisation of weld zone before welding of components.
In order to validate effectiveness of the procedure,
detailed case study is carried out.
The specimens have undergone both destructive and non-
destructive evaluation techniques with
satisfactory/encouraging results.
I. INTRODUCTION
A A2219 ALUMINIUM alloy with copper as main
alloying element is a wonder alloy that meets all
requirements(like specific strength, weldability,
machinability, formability, compatibility, fracture
toughness) of Earth storable as well as Cryo hardware of
space industry and it is widely used for realization of
propellant tank because of its high reliability due to absence
of stress corrosion cracking. However AA2219 is highly
prone for general corrosion and needs proper protection for
long term storage which should also be suitable for critical
process like welding. The present study is for effective
corrosion protection of AA2219 alloy for long term storage
and assessing the effect of the protection process on welding
based on systematic study.
Corrosion of space quality components made of AA2219
can lead to simple problems like thickness loss, poor weld
quality and serious problems like degraded performance /
failure of mission due to blockage of propellants flow by
corrosion products.
The present study is carried out to resolve the issues
ascertained as a result of corrosion/ pitting corrosion noticed
during fabrication of propellant tankages and internal sub-
systems (earth storable and cryogenic tankages and sub-
systems) to be used in Indian launch vehicles viz. Polar
synchronous launch vehicle (PSLV) and Geo-stationary
launch vehicle (GSLV) and GSLV MKIII launch vehicle for
Indian Space Programme. The machined/formed parts of the
tank/internal systems made of AA2219 in T62/T87 temper
condition [Table 1] are fabricated in bulk quantity and
stored as inventory, for welding with the propellant tank and
components. In this process pitting corrosion was seen on
hardware leading to rejections of the same. Furthermore it
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Advanced Materials
was noticed that even minor pitting corrosion at the welding
zone leads to porosity and crack defects in weld which
results in multiple weld re-work passes on the hardware.
This in turn increases residual stresses on the weld, severely
affecting the reliability of the fabricated hardware in use.
High residualstress in propellant tank weld observed during
Proof Pressure Tests (PPT) leads to possibility of hardware
rejection. Hence pitting corrosion of parts as a result of long
term storage before welding is a serious problem. Multiple
studies have been carried out previously to ascertain the
pitting corrosion behaviour of AA2219 alloy [1][2].The
studies have shown that although the addition of copper in
AA2219 alloy increases its strength though precipitate/age
hardening process, it reduces the corrosion resistance of the
alloy. This is due to formation of CuAl 2 and CuAl2Mg
intermetallic phase which being more noble than Al phase
initiates pitting and enhances pitting growth.[3]-[5]
Temper Condition Description
F As Fabricated
T4 Solution Heat treated
T37 T4 + 8% Cold Work
T62 T4 + age 28h at 185oC
T87 T37 + age 24h at 165oC
Table 1.Temper and ageing treatments of AA2219 alloy.
II. PREVIOUS STUDIES CONDUCTED
AA2219 is having the composition as given in Table 2. The
distribution of second phase intermetallic particle and effect
of copper content on the corrosion behaviour is well
researched. [6]-[11].For the scope of the present study
various corrosion protection schemes for AA2219 were
studied:
A. Oil Protection:
The simplest technique which is presently being
followed for components is Oil application. SAE 30 oil is
applied to the fabricated parts and they are covered and kept
for future usage. However oil application is extremely
cumbersome process. Oil gets dried up over a period of time
and thus has to be reapplied at regular interval (every 3
months). Furthermore, due to dust settlement on the surface
of hardware, the protective barrier is damaged resulting in
pitting corrosion.
B. Chromate Conversion Coating [CCC]:
Chromate conversion coating is one of the most
predominantly used method of corrosion protection of
3rd ISSE National Conference on Complex Engineering Systems of National
Importance:Current Trends & Future Perspective (INAC-03), October 12-13, 2017
Advanced Materials

Aluminium.CCC is chromium/chromic acid based coating
for the aluminium metal where the part surface is converted
to a coating for corrosion protection.CCC for Copper rich
alloys of Aluminium which are prone to pitting corrosion
have been studied in details. Hugeset.al. studied CCC on
AA2024-T3 to find the coating to be heterogeneous [12].
Vasquez et. al. also found the CCC on AA2024 to be
heterogeneous and Cu enrichment were found on the outer
most layer of CCC [13]. Hence it is understood that the
coating will have Cu enriched regions which will initiate
localized corrosion in exposure to
environment.MoreoverCCC is carcinogenic and is
hazardous to nature.
C. Anodization:
Anodization is another most predominantly used method
of corrosion protection in Aluminium and its
alloys.Anodization is a electrolytic passivation process
which increase the thickness of natural oxide layer on the
surface of metal parts. Chromic Acid anodisation developed
by Benbough& Stuart [14] and Sulphuric acid anodisation
developed by Kallenborn& Emmons [15] are the two most
commonly used process of anodization for Aluminium.
Previous studies have shown that Chromic Acid anodization
is not recommended for high copper aluminium alloy [16].
Sulphuric acid anodisation method is more suitable for high
copper aluminium alloy like AA2219 which produces a
oxide coating for 6-8m. [17]
study showed that the increase in corrosion resistance is due
to cerium and lanthanum deposits at the site of CuAl 2
intermetallic inclusions.
Conversion coating based on Ce and La are available for
corrosion resistance and are not hazardous like CCC.
However these being special coated with unknown
compounds, their compatibility with various propellants vis
a vis LH2, LOX, N2O4, UDMH, RP-1 have to be studied in
details before qualifying for use in propellant tankages.
Out of the various methods discussed, Sulphuric acid
anodizationis chosen for the present study due to its known
effectiveness for AA219 and easiness in implementation.
III. CHALLENGES FACED
Sulphuric Acid anodization is chosen for protection of
AA2219 alloy from corrosion and its effectiveness is studied
and results obtained are encouraging. However the welding
of aluminium with oxide film has many challenges. The
oxide layer has high melting point and low conductivity. So
welding with oxide layer leads to failure of arc initialization
at the required voltage. In case of partial oxide layer the arc
stabilization issues are faced. Improper cleaning of
oxidelayer is associated with weld defects like high porosity,
lack of fusion and oxide film entrapment. Hence anodisation
layer must be removed at the weld edge either by scrapping
or deanodisation process.
IV. EXPERIMENT DESIGN

D. Alclad: The base material (bare plate) AA2219 was received in

Alclad is the method in which aluminium alloy is
metallurgically bonded on all sides to pure aluminium thin
sheet. Pure aluminium is anodic to aluminium copper
intermetallic phase and thus helps in corrosion resistance.
However this process has its limitation for complex shaped
parts (as in isogrid pockets, complex machined parts, thin
channels, etc.) Furthermore for AA2219 the temperature and
time of thermal treatment should be very carefully Case 1
controlled as prolonged exposure leads to diffusion of
copper to the cladding itself thus making it less anodic and
prone to pitting corrosion [18].
E. Copper Removal:
CuAl2 is removed through AC Anodic Polarization
technique. Thus aluminium surface is corroded protecting
Case 2
the inner metal from corrosion. Copper removal from the
surface of AA2219 has shown good results in increasing the
corrosion resistance of AA2219 [19]. SrinivasRaoet. al.
have studied that Copper Removal along with CCC have
lead to significant increase in pitting corrosion resistance of
AA2219 [20]. However during the same study it is
concluded that the CuAl2removal has no effect on the
Case 3
corrosion resistance of sulphuric acid anodized AA2219.
F. Use of rare earth metal chloride Inhibitors: Fig. 1.Different cases for experimentation.

Due to the carcinogenic nature of chromium used in
CCC, its use is expected to be banned in the near future.
Hence a viable alternative is rare earth metal inhibitors.
Studies by G. Venkatasubramanianet. al. have shown
improved corrosion resistance of AA2219-T87 by use of
chloride of Cerium (Ce) and Lanthanum (La) [21]. The
T87 temper condition having 6mm thickness. The chemical
composition of the bare plate as per Table 2 as reported by
Chemical Analysis. The sheet was cut and machined into
multiple pieces of size 400mm x 120mm x 6mm each. The
Square Butt joint was machined and prepared for DCSP TIG
Welding.

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3rd ISSE National Conference on Complex Engineering Systems of National
Importance:Current Trends & Future Perspective (INAC-03), October 12-13, 2017
Advanced Materials

Mn Si V Fe Ti Cu Mg Zn Zr Al E. Non Destructive Testing

0. 0. 0. 0. 0. 6 0. 0 0 B The welded plates are tested by X-ray using GE
231 082 068 096 038 .33 005 .01 .10 al
9 8
(USA)make radiography machine. The optical density of the
film is maintained within 2.2+15%
Table 2. Chemical Composition of AA2219 alloy The Ultra Sonic Analysis is doneusingKrautkramer
Branson make Ultrasonic Testing Machine. Angle beam
In order to ensure the integrity of the process
ultrasonic A-Scan examination is done on the weld using
experiments/trials with different combinations of the
ultrasonic pulse echo method. AMS 2632 standard is
weldmentsbriefedin Fig 1. Three plates were welded for
followed for the analysis.
each Case and various Non destructive testing and
Dye Penetrant Test is carried out on the weld as per
destructive testing were carriedout.
ASTM-E165.
A. Anodisation
F. Destructive Testing
The plates were cleaned/ degreased with
trichloroethylene. Then the plates were cleaned in Nitric The plates are then cut and machined to prepare Tensile
Acid base de-oxidized solution (Con-5% by volume: De- Strength Specimen for Room Temperature and Cryogenic
oxidizer-6 and Nitric acid 10 to 15%v/v) until no scales Temperature [Fig. 2] as per ASTM B557M and ASTM E8M
were visible on the surface. Then the plates were washed to respectively. The specimens have been taken from the start,
remove any residue of de-oxidizer. The parts were then middle and end of the weld. Room Temperature tensile test
cleaned with De-mineralized water. Complete removal of is carried out on MTS System Corp.,USA make electro-
acid/alkaline was confirmed with litmus paper test. Then the mechanically controlled universal testing machine. Cryo
plates were connected to the anode and inserted in the Temperature tensile test is carried out in LN2 bath.
Sulphuric Acid bath (15% 1% by wt) at a temperature of
202oC. pH of the bath was maintained between 1-3. The
voltage used is 17-18V. The plates were anodized for
45mins. After bringing out, the plates were rinsed with De-
mineralized water to ensure ion free surface. Then sealing of
porous oxide film was done in boiling DM water followed
by De-Masking in acetone. Fig. 2(a) Flat Type Tension Test Specimen (for room
specimen)(ASTM B557M)
B. De-Anodisation of weld edge
The plates undergoing De-Anodization were dipped in nitric
acid based solution used for De-Oxidizer cleaning until no
scales of grey oxide layer is visible. Then the plates were
washed to remove any residue of de-oxidizer. The parts
were then cleaned with De-mineralized water.
C. Welding
For welding the weld edge preparation is done to avoid
Fig. 2(b) Pin Type Tension Test Specimen (for cryo specimen)
the problems associated with improper cleaning discussed
(ASTM E8M)
above. The weld edge are degreased with trichloroethylene
and cleaned with acetone. Then the edge is scraped to
Metallurgical Analysis is done to analyse the metallurgical
remove any oxide or dirt. Difficulty was observed in
structure and finer scale defects which are not detected in
removal of sulphuric acid anodized layer. However with
radiography. Theweldments are cut in transverse section.
second round of scrapping, oxide layer was completely
The samples for macro and micro examination were
eliminated. The surface is checked with Ultra Violet Light
prepared & analyzed in accordance with ASTM E340 &
to find any small trace of Aluminum oxide or dirt left on the
ASTM E112 respectively.The samples arepolished.Macro
surface. The weld joint is positioned with acceptable
samples are etched usingNaOH solution and Micro Samples
mismatch and root gap. The Humidity & Temp is also
are etched using Keller's reagent for metallographic
ensured to be within acceptable range. Auto GTAW is
examination. Microstructural studies were carried out at
carried out in DCSP Mode using Hobart Welders, USA
Weld Zone, Fusion Zone, HAZ and Parent Metal Zone.
make machine according to qualified weld parameters used
for propellant tank welding. AA2319 filler wire is used for G. Corrosion Resistance Test
the welding. Corrosion Resistance is verified with salt spray test. As part
D. Visual Inspection of salt spray test, the test specimen is washed in distilled or
de-ionized water, dried with a soft cloth and then subjected
Visual Inspection of the crown and penetration side of the
to a 5 percent salt spray in accordance with ASTM B 117
weld is to be done to ensure the joint is free from defects
for 336 hrs. [23]
like Undercut, collapse, lack of thickness etc. Weld joint
colorwasalso to be checked.

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Importance:Current Trends & Future Perspective (INAC-03), October 12-13, 2017
Advanced Materials

V. RESULTS AND DISCUSSIONS

A. Visual Inspection Weld Specimen
UTS 0.2% Proof
% Elongation
(MPa) Stress (MPa)
No undercut, collapse or lack of thickness is noticed in
all the welds. The weld is grey in colour which shows good Anodized Plates
353-357 191-208 4.8-5.2
quality of weld. (Case 1)

B. Non-Destructive Testing DeAnodised Plates

352-361 193-208 4.9-5.0
Non-Destructive Evaluation Techniques (NDE) viz. (Case 2)
radiography, dye penetrant tests and ultrasonic tests were
performed. All discontinuities seen in radiographic analysis Bare Plates
367-373 230-231 6.6-7.0
(Case 3)
[Table 3] are minor in nature and acceptable as per standard
followed for ISRO propellant tank fabrication. Ultrasonic
test was carried out by calibrating the instrument using Table 4(b). Mechanical Properties at Cryo Temperature [LN2].
standard rectangular F-notch. No significant defect echo
above 80% was observed. This ensured sound weld quality. D. Metallurgical Analysis
Dye Penetrant test was carried out on both top and under The Macroexamination of weld zone, fusion zone &heat
bead side of the weld and was found satisfactory. affected zone (HAZ) revealed satisfactory fusion and
penetration. The weld is seen to be free from defects like
porosities, lack of fusion and crack. Since it is known that
Radiography Report the AA2219 weld generally fails at the bead edge or weld,
Plate Type
Fine Pores these region was closely studied. Copper rich films are seen
within HAZ of the weld. Grain size in the parent metal,
Anodized Cluster Pores (2.5x2mm) HAZ and width of the HAZ are shown in Table 5. The
Plates
Cluster Pores microstructure of the anodized plate, at various locations
(Case 1)
(1.0*0.7,1.2*1.0,0.5*0.5mm) (Fusion, HAZ & Parent Metal) is given in Fig. 3. Thus it is
clear that there wasno defect in the microstructure as the
Fine Pores
grain recrystalization could be seen in the fusion zone
Cluster Pores (0.5x0.5mm) clearly.
De-Anodized
Plates Cluster Pores (1.0*1.0, Grain Size
Grain
(Case 2) 0.5*0.2,0.8*0.7mm) in parent Approx
Size in HAZ
metal . width of
Fine Pores Weld Specimen (ASTM
(ASTM HAZ
Grain Size
Grain Size (mm)
Bare Plates Fine Pores No.)
No.)
(Case 3) Anodized Plates
Cluster Pores (0.5*0.5,1.0*1.0, 2
(Case 1)
0.5*0.5mm)
De-Anodised
6-7
Plates 5-6 2
(Case 2)
Table 3.Radiography Report of welded specimens
Bare Plates
2.5
Thus the discontinuities observed as a result of (Case 3)
inspection were minor in nature and acceptable.
Table 5: Grain Size & HAZ width
C. Tensile Testing
Tensile test was done at room and cryo temperature to
evaluate the mechanical properties. The values obtained
[Table 4 (a & b)] for Case 1 & 2 meet the requirement and
are equivalent to the bare metal (specimen) welding. The
percentage elongation showed little reduction (2%) for
anodized and de-anodized specimen w.r.t. bare plate
specimen. The loss in ductility may be attributed to presence
of micro oxide particles in the lower surface of the
specimen, which was not removed during scrapping/de-
anodisation process. However the mechanical properties are
well within the acceptable limits with respect to the design
requirement of the hardware.
UTS 0.2% Proof %
Weld Specimen
(MPa) Stress (MPa) Elongation
Anodized Plates (Case 1) 245-254 130-147 5-5.6
De-Anodised Plates (Case 2) 258-268 137-148 4.4-5.0
Bare Plates (Case 3) 248-253 129-137 6.4-6.6
Fig. 3. Microstructure of weld specimen.
Table 4(a). Mechanical Properties at Room Temperature.

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 3rd ISSE National Conference on Complex Engineering Systems of National
Importance:Current Trends & Future Perspective (INAC-03), October 12-13, 2017
Advanced Materials

E. Corrosion Resistance anodisation method locally by incorporating a bath with

In order to ensure the integrity of the specimen with groove of required dimension (as per the dimension of the
respect to corrosion protection, salt spray test was carried weld area for cir-seam and L-seam welds).
out for 336 hrs in the salt spray bath. The results [Table 6] The above study gives the solution for effective protection
shows no corrosion spots were developed (after 336 of AA2219 components for long term storage and method of
hours)on the anodized surface of the weldment as shown in TIG welding for meeting the quality requirements of space
Fig 3. application standards which will ensure the success of
launch missions and improve the reliability of the hardware
Sl Type of for Indian Space program.
Remarks
No. specimen
1 Corrosion spots developed after 24
Anodized Plates hrs at the weldment, however no
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incorporated over scrapping process for handling larger COATINGS, FOR ALUMINUM AND ALUMINUM ALLOYS,
components (viz. tankages of 2.8m and 4m in diameter) as 1993
these hardware would require long weldment, scraping of
which will be extremely ineffective. Alsode-anodising
locally on very large components / sub-assemblies (4000 x
2500 mm) is not possible by conventional method /
facilities. It thereby calls for innovative design of facilities
to provide weld preparation of larger components by de-

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