SCC Susceptibility of Polystyrene/TiO2 Nanocomposite-Coated Thin-Sheet Aluminum Alloy 2024—T3 in 3.5% NaCl

The effectiveness of polystyrene (PS)/TiO2 nanocomposite coatings in reducing stress–corrosion cracking (SCC) susceptibility of aluminum alloy 2024-T3 (AA2024-T3) was evaluated using an accelerated stress–corrosion test. Polystyrene (PS)-based coatings incorporating TiO2 nanoparticles with three different aspect ratios (ARs) were compared to a bare polystyrene coating. A compact tension (CT) specimen (5 mm thick) was coated for testing in a synergistic stress–corrosion environment. A slow constant displacement rate of 1.25 nm/s was applied in the load-line direction of the specimen to gradually open the crack mouth, while the crack tip was periodically dosed with a 3.5 wt.% NaCl solution. Load-displacement data were recorded and analyzed to calculate the J-integral, according to Standard ASTM E1820, for each coated specimen tested under laboratory-controlled SCC conditions. The fracture toughness, stress intensity, and six other SCC susceptibility indices were further developed to compare the performance of each coating in enhancing SCC resistance. The results revealed a strong dependence of SCC resistance on the nanoparticle aspect ratio, with the nanocomposite coating featuring an AR of 1 performing the best. The SCC behavior was reflected in the fractography of the fractured halves of a specimen, where cleavage was observed during the very slow, stable cracking stage, and dimples formed as a result of fast, unstable cracking toward the end of testing. These findings highlight the potential of tailored nanocomposite coatings to enhance the durability of aerospace-grade aluminum alloys.