Characterization of surface integrity of 7075-T6 aluminum alloy subjected to microbiologically induced corrosion during high-speed machining

Microbiologically Influenced Corrosion (MIC) is one of the primary causes of corrosion damage and equipment failure in industrial environments. This paper aims to investigate the impact of microbiologically influenced corrosion on the surface integrity of 7075-T6 aluminum alloy . Through experiments involving cryogenic treatment and machining, the study systematically compares the effects of different microbiologically influenced corrosion environments on 7075-T6 aluminum alloy. Techniques such as X-ray Diffraction (XRD), surface roughness measurement, Scanning Electron Microscopy (SEM), Energy Dispersive Spectroscopy (EDS), and work hardening were used to elucidate the influence of natural seawater (Planktonic microorganisms, PM) and marine sediment (Benthic microorganisms, BM) corrosion on the surface integrity of 7075-T6 aluminum alloy.The results indicate that, compared to PM corrosion, BM corrosion results in a smaller surface roughness of 7075-T6 aluminum alloy. Specifically, the BM-10d specimen exhibits the smallest roughness at 0.353 μm. XRD and EDS analyses show that the corrosion products after microbiological corrosion are primarily a mixture of Al 2 O 3 , AlO(OH), and Al(OH) 3 . The peak intensity of AlO(OH) in the (200) crystal plane of the BM-5d corrosion product is notably higher than that of the 7075-T6 aluminum alloy under other conditions. In the PM environment, the corrosion products fully cover the entire surface of the workpiece and are accompanied by significant cracking. In contrast, in the BM environment, the corrosion products mainly exhibit a granular structure, are scattered across the workpiece surface, and the exposed substrate can be observed.The microhardness of the aluminum alloy after microbiological corrosion shows a trend of increasing initially, then decreasing, and finally stabilizing. The maximum depth of the hardened layer for PM-10d is 120 μm, with a maximum hardness of 178.74 HV. Compared to PM corrosion, BM corrosion results in a significantly greater hardened layer depth for 7075-T6 aluminum alloy, with the BM-10d hardened layer depth reaching approximately 140 μm and the peak hardness at 185.36 HV. Additionally, in the BM environment, the precipitates are fewer compared to those in the PM environment and exhibit a non-continuous, non-grain-boundary precipitation band. • The mechanism of the effect of cryogenic treatment on the residual stress of cutting is still unclear, and the competition mechanism between the internal stress and the residual stress of cutting after cryogenic treatment is an innovation; • The tough-brittle transformation mechanism of cryogenic treatment materials in the cutting process is not clear, and the influence of the microstructure evolution of cryogenic treatment on the tough-brittle transformation is an innovation; • The exploration of the corrosion resistance mechanism of the cutting surface with the synergistic effect of cryogenic treatment and microorganisms is also an innovative contribution.