Simultaneous improvement in the strength and corrosion resistance of Al via high-energy ball milling and Cr alloying

• Synthesis of nanocrystalline Al–Cr alloys via high-energy ball milling
• Consolidation of high-energy ball milled powder using spark Plasma sintering
• Synthesis of Al alloys with ultra-high strength and excellent corrosion resistance
• Suitable alloying elements and processing to optimize corrosion and strength of Al
• Gateway paper to subsequent development of novel Al alloys

The corrosion resistance and mechanical properties of nanocrystalline aluminium (Al) and Al–20 wt.%Cr alloys, synthesized by high-energy ball milling followed by spark plasma sintering, were investigated. Both alloys exhibited an excellent combination of corrosion resistance and compressive yield strength, which was attributed to the nanocrystalline structure, extended solubility, uniformly distributed fine particles, and homogenous microstructure induced by high-energy ball milling. This work demonstrates the possibilities of developing ultra-high strength Al alloys with excellent corrosion resistance, exploiting conventionally insoluble elements or alloying additions via suitable processing routes.

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