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Corrosion of Magnesium, Aluminum, and Steel Automotive Sheet Metals Joined by Steel Self-Pierce Rivets

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Corrosion of Magnesium, Aluminum, and Steel Automotive Sheet Metals Joined by Steel Self-Pierce Rivets Corrosion of Magnesium, Aluminum, and Steel Automotive Sheet Metals Joined by Steel Self-Pierce Rivets THESIS Presented in Partial Fulfillment of the Requirements for the Degree Master of Science in the Graduate School of The Ohio State University By William E. Weimer Graduate Program in Materials Science and Engineering The Ohio State University 2015 Master's Examination Committee: Dr. Gerald Frankel, Advisor Dr. Rudolph Buchheit Copyright by William E. Weimer 2015 Abstract The automotive industry is investigating advanced light-weight materials in an effort to increase the fuel efficiency of vehicles. High-strength steels, aluminum and magnesium alloys, and carbon fiber and polymer composites are of interest to automobile manufacturers around the globe. One of the major problems facing the widespread implementation of such materials, especially aluminum and magnesium alloys, is their unique corrosion susceptibility. Not only is the corrosion performance of aluminum and magnesium alloys different from steel that is typically used in automobile manufacturing, but when used in combined, mixed-material systems, galvanic corrosion becomes a significant concern. The United States Department of Energy, in conjunction with Ford Motor Company, General Motors, and Fiat-Chrysler of America, has established standards that will be enacted to increase the corporate average fuel economy, or fleet-wide average fuel economy, of vehicles to be sold in the United States. This standard is intended to inspire automobile manufacturers to increase the fuel efficiency of vehicles weighing less than 8,500 lbs. The Materials Technology Subprogram of the Vehicle Technologies Office is responsible for the investigation into new advanced materials that will enable technologies to increase fuel efficiency. The United States Automotive Materials Partnership, LLC. has been established with funding from the Department of Energy in ii order to design a magnesium-intensive front-end substructure. The first phase of the project resulted in a 44.5% weight reduction and parts-count reduction from 110 to 47. Now in its third phase, the Partnership has enlisted The Ohio State University in an effort to create a magnesium-intensive front-end demonstration structure, consisting of advanced high-strength steels, aluminum alloys, and magnesium alloys of interest to the original equipment manufacturers participating in the project. The work performed in this thesis has contributed by investigating a case study of an AZ31 cleaning procedure for the MagPASS® conversion coating. Fourier-transform infrared spectroscopy was enlisted to analyze organic compounds on the surface of AZ31 magnesium alloy sheet metal that were interfering with pretreatment uptake. Polymerization of the organic compounds occurred during a warm-forming procedure, causing them to undergo a structural transformation that rendered the cleaning procedure ineffective. The hydrogen embrittlement of hardened-steel rivets coupled to Mg panels was then studied. Considering their close proximity to magnesium alloys, which generate copious hydrogen during corrosion, it was proposed these rivets (RC 47) could potentially experience degradation of mechanical properties. A unique slow-strain-rate hoop-stress-test was designed in an effort to elucidate changes in mechanical properties of the rivets after hydrogen charging. Unfortunately, the non-ideal geometry of the rivets made hydrogen charging ineffectual, and the hoop-stress-test results were inconclusive. iii Finally, changes in lap-shear strength of riveted joints as corrosion dissolved the magnesium surrounding the rivets over time was investigated. It was found that the riveted joints sustained a significant portion of their lap-shear strength despite significant material loss in the adjacent magnesium. It was also found that the industry-standard Zn/Sn-coating for the hardened steel rivets was superior to aluminum-coatings in mitigating the galvanic corrosion. Student-t statistical analysis was employed to establish the statistical significance of the results. iv Dedication This thesis is dedicated to all of those who have allotted their attention and invaluable time towards helping me to complete this work. I would also like to dedicate this work to the United States Department of Energy Vehicle Technology Office Materials Technology Program for initiating this research effort towards achieving better fuel economy in vehicles. Finally, this work is dedicated to the Ford Motor Company for their commitment to sound business practices and intelligent technological foresight. v Acknowledgments First, I owe a deep debt of gratitude towards Dr. Gerald Frankel, my advisor. He has been a wealth of knowledge and a bastion of consistency for me and everyone in his group. His indelible commitment to his own responsibilities, and the vast array of those of each of his students, has been an inspiration to me during my tenure with the Fontana Corrosion Center. As my mentor and role model, Dr. Frankel has continuously exhibited the level of excellence I hope to one day exude. Second, I would like to extend a special thanks to all of the excellent students with whom I have had the pleasure to study. I would like to especially thank those who worked closest with me including PhD candidate Jiheon Jun, Dr. Belinda Hurley, Kerrie Holguin, Brandon Lynch, PhD candidate Jinwook Seong, PhD candidate Pitichon Klomjit, Dr. Severine Cambier, Sara Grieshop, Sara Cantonwine, Sean Morton, PhD candidate Zhicao Feng, PhD candidate Xiaolei Guo, Jermaine Onye, Daniel Kaminski, and Dan Campbell. Third, I would like to acknowledge the help and support of both the people and organizations affiliated with the United States Automotive Materials Partnership. I would like to especially thank Dr. Robert C. McCune of Robert C. McCune and Associates, LLC, who proved to be a patient, practical, and personable resource to me throughout the project. Thank you to Joy Hines Forsmark of Ford Motor Company who was consistently helpful and willing to extend herself and her resources to help me achieve my goals. vi Thank you to Jeff Stalker and John Love of PPG, who were always friendly, supportive, and willing to send materials and advice without hesitation. Finally, thank you to Chris Jurey of Luke Engineering and Bruce Davis of Magnesium Elektron for their support and advice. Fourth, I would like to thank the dedicated human resources support staff, and innovative building and laboratory staff of the Department of Materials Science and Engineering. Thank you to Mei Wang, Mark Cooper, and Megan Daniels for all your advice on the logistics of travel and purchasing, and for your flexibility in helping me through extenuating circumstances. A special thanks to Kenneth Kushner, Steven Bright, and Ross Baldwin, who proved time-and-again to be three of my most valuable colleagues during the pursuit of both my undergraduate and graduate degrees. All three afforded me extensive access to their department resources, knowledge, and expert advice, while maintaining a friendly and approachable demeanor. Fifth, I would like to thank the faculty of The Ohio State University College of Engineering for their substantial support and expert advice. Special thanks go to Associate Professor Dr. Mark Ruegsegger of the Biomedical Engineering department. Dr. Ruegsegger helped me with several meetings, much endearing advice, and access to his Fourier Transform Infrared Spectrometer at no cost. Thank you to Professor Rudolph Buchheit for always being helpful, encouraging, and willing to allow me access to his vast knowledge of the corrosion field; thank you also, to Dr. Buchheit, for his role as the second member of my thesis committee. Thank you to Professor David Tomasko of the Department of Chemical and Biomolecular Engineering for his advice, encouragement, vii and resources. Also, thank you to Dr. Alison Polasik of the Department of Materials Science and Engineering for advice and encouragement. Sixth, I would like to acknowledge the incredible amount of personal and professional support I received from those in the Human Resources Department of the Ohio State University College of Engineering. Thank you, especially, to Amy Franklin and Winifred Sampson for their continuous encouragement, emotional support and advice, and willingness to listen; I truly could not have made it without them. Finally, I would like to thank my parents. Without their unconditional love and support throughout my pursuit of degrees, I would not be able to undertake the next step: my pursuit of happiness. viii Vita 2001-2005 ......................................................Pickerington High School Central 2006-2011 ......................................................Soil Testing and Engineering, Ltd, Quality Control/Quality Assurance Technician 2011-2012 ......................................................Material Advantage, Treasurer, The Ohio State University 2011................................................................Engineers’ Council, Treasurer, The Ohio State University 2012................................................................Engineers’ Council, President, The Ohio State University 2012................................................................Engineering Career Expo, Student Coordinator, The Ohio State University 2009-2012 ......................................................B.S. Materials Science and Engineering, The Ohio State University 2012-present ...................................................Graduate
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