Corrosion of Additively Manufactured Alloys: A Review

Abstract

Additive manufacturing (AM), often termed 3D printing, has recently emerged as a mainstream means of producing metallic components from a variety of metallic alloys. The numerous benefits of AM include net shape manufacturing, efficient use of material, suitability to low volume production runs, and the ability to explore alloy compositions not previously accessible to conventional casting. The process of AM, which is nominally performed using laser (or electron) based local melting, has a definitive role in the resultant alloy microstructure. Herein, the corrosion of alloys prepared by AM using laser and electronbased methods, relating the corrosion performance to the microstructural features influenced by AM processing, are reviewed. Such features include unique porosity, grain structures, dislocation networks, residual stress, solute segregation, and surface roughness. Correlations between reported results and deficiencies in present understanding are highlighted.

Corrosion of metallic materials fabricated by selective laser melting

“…The effects of the printing parameters on the microstructure and defect evolution during rapid solidification are widely reported, and the optimised printing parameters can usually lead to better mechanical properties. [55][56][57] However, the corrosion behaviour and durability of the selective laser melted (SLMed) parts have not drawn considerable attention to date yet [58][59][60][61][62] and the understanding of the underlying corrosion mechanisms of the SLMed metals and alloys still remains in its infancy. It is well acknowledged that corrosion leads to an annual financial loss of US$4 trillion globally due to corrosion damage and corrosion protection investment.…”

Evaluation of Corrosion Resistance of Alloy 625 Obtained by Laser Powder Bed Fusion

“…Specifically, whist building orientations were not shown to play an important effect on the corrosion behavior, 37 improved corrosion resistance with respect to conventionally produced components was reported. 38 However, according to the authors' knowledge, in the literature there is no data about the corrosion resistance of Alloy 625 processed by LPBF or other additive manufacturing techniques. Therefore, the aim of this paper was to evaluate the localized corrosion (pitting and crevice) resistance of Alloy 625 samples manufactured via LPBF and compare it with the behavior of materials manufactured via conventional routes.…”

Corrosion of Cast Aluminum Alloys: A Review

“…Thus, it can be advanced that all issues that affect microstructural changes and induce defects into material affect corrosion susceptibility. Recently, Sander et al [66] conducted a state of the art review to know the scenarios of corrosion of AM alloys, noting that features associated with their own process lead to being potential nucleation corrosion sites, such as dislocation networks, grain directionality, solute segregation, porosity, oxides and atypical inclusions, surface roughness, residual stresses, etc. [23].…”