Cormulayer Aluminum (Corrosion Resistant Multi-Layer Aluminum) that is a three layer structure with a base of a 7000 series alloy; an intermediate layer of a soft, corrosion sacrificial layer of high lithium content-aluminum or high magnesium content-aluminum alloy; and a top layer for corrosion resistance of a 5000 series alloy. The base layer provides the strength for the sandwich and the top layer provides strength and general corrosion resistance. The intermediate layer is for both providing corrosion resistance to the base 7000 layer and for stopping cracks from propagating through the layered structure. This intermediate layer is cathodic to the other layers and will provide general cathodic protection and will turn corrosion pits from continuing through to the base 7000 series aluminum layer. The layered sheet and plate will have similar or improved fatigue resistance compared to the 7075-T7 / 7050-T7 with comparable strength. Thermal spray deposition is used to develop the corrosion resistant aluminum layered structure. These coupons and plates are used for corrosion testing. The best performing alloy combinations are then fabricated using roll forming techniques with heat treatment for confirming corrosion tests and for fatigue tests.
Keywords: Aluminum Alloy, Layered Aluminum Structures, Corrosion, Metal, Aluminum Alloy, Microstructure, Thermo-Mechanical Processing, 7000 Series Aluminum Alloy
