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The effect of V addition on the hardness and corrosion of aluminum alloy 2024 (AA2024) produced by high‐energy ball milling has been investigated. High‐energy ball milled alloys exhibited enhanced solid solubility of alloying elements and ultrafine grains. The addition of V improved the corrosion resistance of the AA2024 alloy, which was attributed to the deposition of V on the cathodic particles and therefore decrease in their ability to sustain large cathodic currents.

Supersaturated solid solutions of Al and corrosion-resistant alloying elements (M: V, Mo, Cr, Ti, Nb), produced by non-equilibrium processing techniques, have been reported to exhibit high corrosion resistance and strength. The corrosion mechanism for such improved corrosion performance has not been well understood. We present a fundamental understanding of the role of V in corrosion of an Al-V alloy, which will provide a theoretical background for developing corrosion-resistant Al alloys. High-energy ball milling of the elemental powder of Al and V produced an in situ consolidated Al-V alloy, which exhibited high solid solubility of V. The corrosion resistance of Al-V alloy was significantly higher than that of pure Al, which was attributed to the (1) enrichment of V at the passive film/substrate interface, (2) incorporation of V into the passive film, and (3) deposition of V on the iron-containing cathodic particles and therefore, retardation of cathodic reaction.