This study utilizes desalted and denitrated treated aluminum dross (TAD) as a raw material, along with kaolin and 10 ppi (pores per inch) polyurethane foam as a template. The slurry is converted into an aluminum dross green body with a three-dimensional network structure using the impregnation method. A three-dimensional network aluminum dross ceramic framework (TAD3D) is created at a sintering temperature of 1350 °C. The liquid 5A05 aluminum alloy at a temperature of 950 °C infiltrates into the voids of TAD3D through pressureless infiltration, resulting in TAD3D/5A05Al composite material with an interpenetrating phase composite (IPC) structure. The corrosion behavior of TAD3D/5A05 composite material in sodium chloride solution was examined using the salt spray test (NSS) method. The study shows that the pores of the TAD3D framework, produced by sintering aluminum dross as raw material, are approximately 10 ppi. The bonding between TAD3D and 5A05Al interfaces is dense, with strong interfacial adhesion. The NSS corrosion time ranged from 24 h to 360 h, during which the composite material underwent pitting corrosion, crevice corrosion and self-healing processes. Results from Potentiodynamic Polarization (PDP) and Electrochemical Impedance Spectroscopy (EIS) indicate that, as corrosion progresses, the Ecorr of TAD3D/5A05Al decreases from -0.718 V to -0.786 V, and Icorr decreases from 0.398 μA·cm-2 to 0.141 μA·cm-2. A dense oxide film forms on the surface of the composite material, increasing the anodic Tafel slope and decreasing the cathodic Tafel slope, thus slowing down the rates of cathodic and anodic reactions. Factors such as lower interface corrosion resistance or a relatively weak passivation film at the interface do not significantly diminish the corrosion resistance of TAD3D and 5A05Al. The corrosion resistance of the composite material initially decreases and then increases.
Keywords: TAD3D/5A05Al; aluminum dross; composite; corrosion behavior; electrochemistry; neutral salt spray.