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The corrosion behavior of selective laser melted (SLM) 304L was investigated and compared to conventional wrought 304L in aqueous chloride and acidic solutions. Through immersed electrochemical testing and exposure in acidic solutions, the SLM 304L exhibited superior pitting resistance in the polished state compared to wrought 304L. However, the surface condition of the SLM material had a great impact on its corrosion resistance, with the grit-blasted condition exhibiting severely diminished pitting resistance. Local scale, capillary micro-electrochemical and scanning electrochemical microscopy investigations, identified porosity as a contributing factor to decreased corrosion resistance. Preferential corrosion attack was not observed to be related to the characteristic underlying cellular microstructure produced through SLM processing. This study highlights the effects of SLM microstructural features on corrosion resistance, specifically the substantial influence of surface finish on SLM corrosion behavior and the need for development and optimization of processing techniques to improve surface finish. Powder bed selective laser melting (SLM) has become a desirable and widely used technique for the additive manufacturing (AM) of metal parts. While a significant amount of research has been carried out on the mechanical properties of SLM materials, little is known regarding their corrosion behavior. Of the few corrosion studies that do exist, the primary focus has been on evaluating general corrosion resistance.1,2 A few recent investigations have examined the role of processing and microstructure on the material corrosion behavior in more detail.3,4 However, there is still a need for further investigation in order to develop a full understanding of the microstructural and morphological characteristics inherent to AM materials due to the unique processing conditions and their relative contributions to the materials' corrosion behavior. Ideally, a ranking of the deleterious or advantageous properties formed in AM materials with respect to corrosion should be established. This is necessary for a variety of alloy systems in engineering relevant solutions and environments to help inform and guide future processing parameters, build designs, and materials selection.The powder bed process along with extremely high cooling rates and temperature gradients during SLM processing create microstructures and part surfaces that differ greatly from their conventional thermo-mechanically processed counterparts. Several characteristics are expected or have known effects on corrosion behavior including surface finish, porosity, inclusions (MnS, oxides, etc.), and microstructures formed through non-equilibrium cooling conditions. For example, a strong relationship between surface roughness and corrosion susceptibility has been observed in which pit initiation decreases with decreasing surface roughness in chloride solutions.5-7 Porosity, formed by entrapped gas or lack of fusion of powder particles in the SLM build, can also reduce...

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The natural convection boundary layer ( δ n c ) and its influence on cathodic current in a galvanic couple under varying electrolytes as a function of concentration (1 − 5.3 M NaCl) and temperature (25 °C−45 °C) were understood. Polarization scans were obtained under quiescent conditions and at defined boundary layer thicknesses using a rotating disk electrode on platinum and stainless steel 304L (SS304L); these were combined to determine δ n c . With increasing chloride concentration and temperature, δ n c decreased. Increased mass transport (Sherwood number) results in a decrease in δ n c , providing a means to predict this important boundary. Using Finite Element Modeling, the cathodic current was calculated for an aluminum alloy/SS304L galvanic couple as a function of water layer (WL) thickness and cathode length. Electrolyte domains were delineated, describing (i) dominance of ohmic resistance over mass transport under thin WL, (ii) the transition from thin film to bulk conditions at δ n c , and (iii) dominance of mass transport under thick WL. With increasing chloride concentration, cathodic current decreased due to decreases in mass transport. With increasing temperature, increased cathodic current was related to increases in mass transport and solution conductivity. This study has implications for sample sizing and corrosion prediction under changing environments.

Atomic hydrogen (H) was introduced into steel (AISI 1018 mild steel) by controlled cathodic pre-charging. The resultant steel sample, comprising about 1 ppmw diffusible H, and a reference uncharged sample, were studied using atomic emission spectroelectrochemistry (AESEC). AESEC involved potentiodynamic polarisation in a flowing non-passivating electrolyte (0.6 M NaCl, pH 1.95) with real time reconciliation of metal dissolution using on-line inductively coupled plasma-atomic emission spectroscopy (ICP-OES). The presence of absorbed H was shown to significantly increase anodic Fe dissolution, as evidenced by the enhanced detection of Fe2+ ions by ICP-OES. We discuss this important finding in the context of previously proposed mechanisms for H-effects on the corrosion of steels.

Ground 304 stainless steel (SS) samples were exposed to sea salt particles at 35 °C and two relative humidity (RH) levels for durations ranging from 1 week to 2 years. For all exposure times, pit number density and total pit volume at 40% RH were observed to be considerably greater than those at 76% RH. Statistical analysis of distributions of pit populations for both RH conditions showed that pit number density and total pit volume increased rapidly at first but slowed as exposure time increased. Cross-hatched features were observed in the 40% RH pits while ellipsoidal, faceted pits were observed at 76% RH. Optical profilometry indicated that most pits were not hemispherical. X-ray tomography provided evidence of undercutting and fissures. Piecewise curve fitting modeled the 40% RH data closely, predicting that corrosion damage would eventually plateau. However, a similar treatment of the 76% RH data suggested that corrosion damage would continuously increase, which implied that the piecewise power-law fit was limited in its ability to model atmospheric corrosion generally. Based on these observations, the operative mechanisms determining long-term corrosion behavior were hypothesized to be different depending on the RH of exposure.

Aluminum and aluminum alloys are widely used in many outdoor applications due to their inherent corrosion resistance attributed to the formation of a protective oxide layer. While corrosion rates are generally considered low for aluminum in many atmospheric environments, understanding of the corrosion performance over time is necessary to predict the cost, safety, and esthetics of these materials. The vast majority of the knowledgebase of atmospheric aluminum corrosion is built on environment-response relationships; often based on statistical correlation of corrosion rate data with atmospheric environmental conditions. However, there is still a limited mechanistic understanding of corrosion processes associated with this linkage. This lack in knowledge prevents interpretation and limits the extrapolation of these statistical datasets for prediction purposes. Here, the mechanistic dependence of aluminum corrosion rate on salt loading is explored through complimentary experimental and theoretical analysis relating corrosion rate to electrolyte chemistry, volume and corrosion products. From these results a reaction pathway is proposed for the atmospheric corrosion of aluminum that accounts for the governing effects of CO 2 and salt loading on corrosion rate. This reaction pathway provides a new perspective that highlights the importance of the formation and growth of dawsonite (NaAlCO 3 (OH) 2 ), and the subsequent gettering of sodium from the electrolyte leading to the stifling of corrosion kinetics. This study highlights the importance of accounting for the dynamic physical and chemical state of the electrolyte during corrosion in process models and measurement techniques to better understand and predict atmospheric corrosion behavior.