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Corrosion and Corrosion Protection of Additively Manufactured Alloys
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Corrosion and Corrosion Protection of Additively Manufactured Alloys

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Corrosion".

Deadline for manuscript submissions: closed (20 April 2023) | Viewed by 7559

Special Issue Editors

Dr. Reynier I. Revilla

E-Mail Website
Guest Editor
Research Group Electrochemical & Surface Engineering, Vrije Universiteit Brussel, Brussels, Belgium
Interests: materials characterization; corrosion; surface treatment; corrosion protection; metal additive manufacturing; scanning probe microscopy
Prof. Dr. Iris De Graeve

E-Mail Website
Guest Editor
Research Group Electrochemical & Surface Engineering, Vrije Universiteit Brussel, Brussels, Belgium
Interests: surface engineering; corrosion; corrosion protection; surface treatment; metal additive manufacturing

Special Issue Information

Dear Colleagues,

Metal additive manufacturing (MAM), a process by which complex multifunctional metal parts are produced in a layer-by-layer fashion, is considered one of the enabling technologies for Industry 4.0. This technology has attracted a great deal of attention in recent years and has found numerous applications in such industries as medical implants, energy, aerospace, and automotive because it allows near-net-shape manufacturing of geometrically complex parts. It has also shown great potential for applications in repair. Nowadays, a great number of metals and alloys can be processed by MAM.

Due to the special conditions associated with MAM (for instance, small melt pools, rapid solidification, and the use of pre-alloyed metal feedstock), a very fine microstructure with unique directional growth features far from equilibrium is generally obtained. This distinctive microstructure, together with defects originating from the MAM process, is known to greatly influence the performance and corrosion behavior of these materials. Therefore, this Special Issue focuses on the complex relationship between the microstructure, post-thermal treatments, and defect characteristics of MAM processes such as surface roughness, porosity, and internal residual stresses on the corrosion behavior of additively manufactured (AM) metal parts. Additionally, studies dedicated to the analysis of corrosion protection mechanisms and surface treatments for AM alloys are highly welcome.

Dr. Reynier I. Revilla
Prof. Dr. Iris De Graeve
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • corrosion
  • metal additive manufacturing
  • microstructure
  • localized corrosion
  • corrosion protection
  • heat treatment

Published Papers (5 papers)

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Research

20 pages, 13216 KiB  
Article
Changes in the Structure and Corrosion Protection Ability of Porous Anodic Oxide Films on Pure Al and Al Alloys by Pore Sealing Treatment
by Haruno Yanagimoto, Koki Saito, Hideaki Takahashi and Makoto Chiba
Materials 2022, 15(23), 8544; https://doi.org/10.3390/ma15238544 - 30 Nov 2022
Cited by 4 | Viewed by 1542
Abstract
It is well known that corrosion protection of pure Al is enormously improved by the formation of porous anodic oxide films and by pore sealing treatment. However, the effects of anodizing and pore sealing on corrosion protection for Al alloys are unclear, because [...] Read more.
It is well known that corrosion protection of pure Al is enormously improved by the formation of porous anodic oxide films and by pore sealing treatment. However, the effects of anodizing and pore sealing on corrosion protection for Al alloys are unclear, because the alloying elements included in Al alloys affect the structure of anodic oxide films. In the present study, porous anodic oxide films are formed on pure Al, 1050-, 3003- and 5052-Al alloys, and pore sealing was carried out in boiling water. Changes in the structure and corrosion protection ability of porous anodic oxide films on pure Al and the Al alloys by pore sealing, were examined by scanning electron microscopy (SEM) and electrochemical impedance spectroscopy (EIS). SEM observation showed that anodic oxide films formed on pure Al have a smooth surface after pore sealing, and that cracks are formed in anodic oxide films on 1050-, 3003- and 5052-aluminum alloys, after pore sealing. Corrosion protection after pore sealing increased with anodizing time on pure Al, but only slightly increased with anodizing time on the Al alloys. Full article
(This article belongs to the Special Issue Corrosion and Corrosion Protection of Additively Manufactured Alloys)
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16 pages, 6858 KiB  
Article
Microstructural Features, Defects, and Corrosion Behaviour of 316L Stainless Steel Clads Deposited on Wrought Material by Powder- and Laser-Based Direct Energy Deposition with Relevance to Repair Applications
by Reynier I. Revilla and Iris De Graeve
Materials 2022, 15(20), 7181; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15207181 - 14 Oct 2022
Cited by 3 | Viewed by 1358
Abstract
This work analyses the microstructural defects and the corrosion behaviour of 316L stainless steel clads deposited by laser metal deposition on wrought conventional material, which is a highly relevant system for repair applications. The different defects and microstructural features found in these systems [...] Read more.
This work analyses the microstructural defects and the corrosion behaviour of 316L stainless steel clads deposited by laser metal deposition on wrought conventional material, which is a highly relevant system for repair applications. The different defects and microstructural features found in these systems were identified and analysed from a perspective relevant to the corrosion performance of these materials. The role of these features and defects on the corrosion process was evaluated by exposure of the samples to corrosive media and further examination of the corrosion morphology. The heat-affected zone, located on the wrought base material in close vicinity of the deposited clad, was identified to be the primary contributor to the corrosion activity of the system due to the large depletion of alloying elements in this region, which significantly decreased its pitting resistance. Alongside the heat-affected zones, relatively small (<30 µm in diameter) partially un-melted powder particles scattered across the surface of the clad were systematically identified as corrosion initiation spots, possibly due to their relatively high surface energy and therefore high reactivity compared to larger powder particles. This work highlights the need for more investigations on as-built surfaces of additively manufactured parts to better explore/understand the performance of the materials closer to their final applications. It demonstrates that the surface defects resulting from the additive manufacturing process, rather than the presence of the refined sub-granular cellular structure (as highlighted in previous works), play the predominant role in the corrosion behaviour of the system. Full article
(This article belongs to the Special Issue Corrosion and Corrosion Protection of Additively Manufactured Alloys)
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16 pages, 6454 KiB  
Article
Correlation of Lack of Fusion Pores with Stress Corrosion Cracking Susceptibility of L-PBF 316L: Effect of Surface Residual Stresses
by Arshad Yazdanpanah, Mattia Franceschi, Pietro Rebesan and Manuele Dabalà
Materials 2022, 15(20), 7151; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15207151 - 14 Oct 2022
Cited by 3 | Viewed by 1280
Abstract
Stress corrosion cracking (SCC) of laser powder bed fusion-fabricated 316L was studied under the variation in energy input density to emulate the existence of distinctive types of defects. Various electrochemical polarization measurements were performed in as-received polished and ground states, to elucidate the [...] Read more.
Stress corrosion cracking (SCC) of laser powder bed fusion-fabricated 316L was studied under the variation in energy input density to emulate the existence of distinctive types of defects. Various electrochemical polarization measurements were performed in as-received polished and ground states, to elucidate the effect of defect type on corrosion and SCC behaviour in marine solution. The results revealed severe localized corrosion attack and SCC initiation for specimens with a lack of fusion pores (LOF). Moreover, the morphology of SCC was different, highlighting a more dominant effect of selective dissolution of the subgrain matrix for gas porosities and a more pronounced effect of brittle fracture at laser track boundaries for the specimens with LOF pores. Full article
(This article belongs to the Special Issue Corrosion and Corrosion Protection of Additively Manufactured Alloys)
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19 pages, 4281 KiB  
Article
Susceptibility to Pitting and Environmentally Assisted Cracking of 17-4PH Martensitic Stainless Steel Produced by Laser Beam Melting
by Nizar Guennouni, Daniel Maisonnette, Christophe Grosjean, Dominique Poquillon and Christine Blanc
Materials 2022, 15(20), 7121; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15207121 - 13 Oct 2022
Cited by 4 | Viewed by 1357
Abstract
Materials produced by additive manufacturing (AM) often have different microstructures from those obtained using conventional metallurgy (CM), which can have significant impacts on the materials’ durability, and in particular, resistance to corrosion. In this study, we were concerned with the susceptibility to pitting [...] Read more.
Materials produced by additive manufacturing (AM) often have different microstructures from those obtained using conventional metallurgy (CM), which can have significant impacts on the materials’ durability, and in particular, resistance to corrosion. In this study, we were concerned with the susceptibility to pitting and environmentally assisted cracking (EAC) of 17-4PH martensitic stainless steel (MSS). We focused on the evolution from pitting to EAC, and the behaviour of MSS produced by AM was compared with that of its CM counterpart. Potentiodynamic polarisation tests were combined with chronoamperometry measurements performed without and with mechanical loading to study both stable and metastable pitting and the influence of stress on these processes. EAC tests were carried out and combined with observations of fracture surfaces. MSS produced by AM was more resistant to pit initiation due to fewer and finer NbC particles. However, the propagation kinetics of stable pits were higher for this MSS due to a higher amount of reversed austenite. The stress was found to stabilise the metastable pits and to accelerate the propagation of stable pits, which resulted in an increased susceptibility to EAC of the MSS produced by AM. These results clearly highlighted the fact that the reversed austenite amount has to be perfectly controlled in AM processes. Full article
(This article belongs to the Special Issue Corrosion and Corrosion Protection of Additively Manufactured Alloys)
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17 pages, 7063 KiB  
Article
Effect of Thermal Treatment on Corrosion Behavior of AISI 316L Stainless Steel Manufactured by Laser Powder Bed Fusion
by Francesco Andreatta, Alex Lanzutti, Reynier I. Revilla, Emanuele Vaglio, Giovanni Totis, Marco Sortino, Iris de Graeve and Lorenzo Fedrizzi
Materials 2022, 15(19), 6768; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15196768 - 29 Sep 2022
Cited by 5 | Viewed by 1407
Abstract
The effect of post-processing heat treatment on the corrosion behavior of AISI 316L stainless steel manufactured by laser powder bed fusion (L-PBF) is investigated in this work. Produced stainless steel was heat treated in a broad temperature range (from 200 °C to 1100 [...] Read more.
The effect of post-processing heat treatment on the corrosion behavior of AISI 316L stainless steel manufactured by laser powder bed fusion (L-PBF) is investigated in this work. Produced stainless steel was heat treated in a broad temperature range (from 200 °C to 1100 °C) in order to evaluate the electrochemical behavior and morphology of corrosion. The electrochemical behavior was investigated by potentiodynamic and galvanostatic polarization in a neutral and acidic (pH 1.8) 3.5% NaCl solution. The microstructure modification after heat treatment and the morphology of attack of corroded samples were evaluated by optical and scanning electron microscopy. The fine cellular/columnar microstructure typically observed for additive-manufactured stainless steel evolves into a fine equiaxed austenitic structure after thermal treatment at high temperatures (above 800 °C). The post-processing thermal treatment does not negatively affect the electrochemical behavior of additive-manufactured stainless steel even after prolonged heat treatment at 1100 °C for 8 h and 24 h. This indicates that the excellent barrier properties of the native oxide film are retained after heat treatment. Full article
(This article belongs to the Special Issue Corrosion and Corrosion Protection of Additively Manufactured Alloys)
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