Effect of Film Thickness and Defects on the Corrosion Behavior of Anodic Oxide Films on Aluminum Alloys

This study focuses on sulfuric acid-anodized films formed on 2A12 and 6061 aluminum alloys, in which the corrosion behavior of the oxide films under different film thicknesses, sealing methods, and defect states was investigated through neutral salt spray testing combined with surface morphology characterization and XRD analysis. The results indicate that the corrosion resistance of anodic oxide films is positively correlated with film thickness, while the anodized film on 2A12 aluminum alloy contains more cracks than that on 6061, which can readily serve as long-term corrosion initiation sites. Although the corrosion products of both alloys are identified as Al₂O₃ and AlO(OH), the oxide films on 6061 aluminum alloy exhibit higher compactness than those on 2A12 at all investigated thicknesses, resulting in superior resistance to neutral salt spray corrosion, and both sealing methods provide effective protection for the 6061 aluminum alloy substrate. This study provides experimental and theoretical references for the development and application of anodizing processes for aluminum alloys in chloride-containing marine environments.