Corrosion Behavior of Al–Cu Alloy by Room-Temperature Random Vibration

Intergranular corrosion (IGC) and exfoliation corrosion (EXCO) limit the durability of 2219 Al–Cu in chloride-rich, cyclic-humidity aerospace environments, and conventional thermal stress relief can worsen grain boundary precipitates and grain boundary non-precipitation zones (PFZs), motivating evaluation of low-temperature resonant vibration stress relief. Using polarization tests and microstructural analysis, we show that RRV lowers corrosion current, strengthens passivation, and reduces IGC and EXCO susceptibility. Alternating tensile–compressive stresses build dislocation networks that convert continuous or semi-continuous grain boundary precipitates into discrete distributions, increasing corrosion path tortuosity and slowing intergranular attack. A more discrete cathodic phase, a narrowed solute-enriched anodic band, and reduced PFZs disrupt corrosion channel continuity, weaken microgalvanic driving forces via a more uniform θ′ distribution, and limit corrosion product wedging, while homogenized precipitates suppress local galvanic coupling in EXCO-like media. Overall, RRV synergistically optimizes dislocation configuration and precipitate redistribution to intrinsically enhance corrosion resistance and offers a practical, low-temperature, scalable route to improve the durability of high-strength aluminum alloy structures in aerospace service.