Fabrication of corrosion-resistant ZL205A aluminum alloys thin-wall using WAAM: Exploring the synergistic effects of FSP and multidimensional nanomaterials

ZL205A aluminum alloys are favored for essential structural components in marine and aerospace sectors because of their superior strength-to-weight ratio. Yet, their vulnerability to corrosion in severe marine conditions presents a notable challenge. Although Wire Arc Additive Manufacturing (WAAM) enables the production of complex ZL205A components, maintaining their corrosion resistance is still a critical concern. This research explores the combined impact of Friction Stir Processing (FSP) and multidimensional nano-reinforcement on the microstructure and corrosion resistance of ZL205A thin-walled parts produced via WAAM. ZL205A thin-walled components, fabricated using Cold Metal Transfer (CMT)-based WAAM, underwent FSP, both with and without BNNS@Al 2 O 3 multidimensional nanomaterials. Our findings indicate that FSP considerably refines the grain structure and reduces the porosity typical of the WAAM process. Incorporating BNNS@Al 2 O 3 nanomaterials during FSP significantly enhanced grain refinement. These nanomaterials formed a network-like barrier within the matrix, effectively isolating the aluminum alloy from corrosive agents. The optimized microstructure results in significant corrosion resistance improvements; nano-reinforced specimens showed a 23-fold decrease in corrosion weight loss rate under salt spray conditions and a 352.58 % increase in equivalent resistance compared to traditional cast ZL205A. The findings highlight the potential of integrating WAAM, FSP, and multidimensional nano-reinforcements to develop high-performance ZL205A components with enhanced corrosion resistance, facilitating broader application in demanding environments.