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Corrosion in Additive Manufacturing
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Corrosion in Additive Manufacturing

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

Deadline for manuscript submissions: closed (20 October 2022) | Viewed by 12295

Special Issue Editors

Dr. Raul Figueroa

E-Mail Website
Guest Editor
Department of Materials Engineering, Applied Mechanics and Construction, University of Vigo, Vigo, Spain
Interests: material characterization; microstructure; coatings; sol-gel; surface engineering; tribology; wear testing; corrosion; electrochemical impedance; electrodeposition
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Rhys Jones

E-Mail Website
Guest Editor
1. Department of Mechanical and Aerospace Engineering, Monash University Clayton, Clayton, VIC 3800, Australia
2. ARC Industrial Transformation Training Centre on Surface Engineering for Advanced Materials, Faculty of Science, Engineering and Technology, Swinburne University of Technology, John Street, Hawthorn, VIC 3122, Australia
Interests: ageing aircraft; composites; bonded structures; fatigue and failure; additive manufacturing; cold spray
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Additive manufacturing (AM, commonly known as 3D printing) has greatly advanced in recent years due to its ability to manufacture parts of great complexity and adequate precision. The different manufacturing methodologies offer another series of advantages such as: the efficient use of materials, the manufacture of a large number of materials, as well as the research of new ones. Its application is present in different industrial fields that include sectors as diverse as medicine and construction, using all kinds of materials.

Despite the great development and the large number of investigations carried out in this topic, the optimization of the manufacturing processes is still necessary. The microstructural changes, the presence of defects and the anisotropy in the properties, condition the final properties and therefore their applicability. Many of the existing investigations limit the characterization of these materials to mechanical behavior, although we cannot forget that degradation processes, such as corrosion in metals, largely condition their applications.

This Special Issue focuses on the corrosion resistance of metallic materials and metallic matrix materials obtained by additive manufacturing. Topics of interest include, but are not limited to:

  • Correlation between microstructure, manufacturing defects, surface finish and electrochemical response
  • Optimization or simulation of AM to improve the properties against corrosion
  • Electrochemical response of new AM materials
  • Advancements in degradation of AM materials

Dr. Raul Figueroa
Prof. Dr. Rhys Jones AC
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

  • additive manufacturing
  • 3D printing
  • materials engineering, corrosion
  • microstructure
  • stress–corrosion cracking

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Published Papers (5 papers)

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Research

13 pages, 5406 KiB  
Article
Corrosion Resistance of 316L/CuSn10 Multi-Material Manufactured by Powder Bed Fusion
by Robert Kremer, Johannes Etzkorn, Heinz Palkowski and Farzad Foadian
Materials 2022, 15(23), 8373; https://doi.org/10.3390/ma15238373 - 24 Nov 2022
Cited by 5 | Viewed by 1833
Abstract
Research and industry are calling for additively manufactured multi-materials, as these are expected to create more efficient components, but there is a lack of information on corrosion resistance, especially since there is a risk of bimetallic corrosion with two metallic components. In this [...] Read more.
Research and industry are calling for additively manufactured multi-materials, as these are expected to create more efficient components, but there is a lack of information on corrosion resistance, especially since there is a risk of bimetallic corrosion with two metallic components. In this study, the corrosion behaviour of a multi-material made of 316L and CuSn10 is investigated before and after a stress relief annealing using linear sweep voltammetry. For this purpose, a compromise had to be found in the heat treatment parameters in order to be able to treat both materials together. In addition, additively manufactured and rolled samples were investigated and used as a reference. Interaction of the two materials in the multi-material could be demonstrated, but further investigations are necessary to clearly assess the behaviour. In particular, the transition region of the two materials should be investigated. In this study, a stress relief heat treatment at 400 °C caused a slight improvement in the corrosion resistance and reduced the scatter of the measurements significantly. No significant difference was measured between the additively produced and rolled samples. Full article
(This article belongs to the Special Issue Corrosion in Additive Manufacturing)
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11 pages, 7091 KiB  
Article
The Behavior of a Zn-Al Anticorrosive Coating in the Wiredrawing Process
by Marius Tintelecan, Dana-Adriana Iluțiu-Varvara, Ioana Monica Sas-Boca and Claudiu Aciu
Materials 2022, 15(18), 6190; https://doi.org/10.3390/ma15186190 - 6 Sep 2022
Cited by 1 | Viewed by 1580
Abstract
The present paper describes and quantifies the behavior of a Zn-Al anticorrosive coating deposited on the surface of a steel wire before its drawing process. For the complete evaluation of this behavior, the drawing of these samples was performed on four wiredrawing lines, [...] Read more.
The present paper describes and quantifies the behavior of a Zn-Al anticorrosive coating deposited on the surface of a steel wire before its drawing process. For the complete evaluation of this behavior, the drawing of these samples was performed on four wiredrawing lines, differing by the deformation angle 2 · α of the component dies of each line. For good agreement with industrial practice, the drawing series used a partial reduction of the section of 20%. Two aspects were analyzed: the evolution of the chemical composition and the structure of the removed layer during the drawing of the coated steel wire, and the drawing force necessary to carry out this process. This article helps to elucidate how the Zn-Al anti-corrosion layer responds to the stresses inherent in the process of drawing the steel wire on which it is deposited. Full article
(This article belongs to the Special Issue Corrosion in Additive Manufacturing)
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15 pages, 2137 KiB  
Article
Corrosion Resistance of 3D Printed Ti6Al4V Gyroid Lattices with Varying Porosity
by Rachael Sharp, Matthew H. Pelletier, William R. Walsh, Cambre N. Kelly and Ken Gall
Materials 2022, 15(14), 4805; https://doi.org/10.3390/ma15144805 - 9 Jul 2022
Cited by 9 | Viewed by 2542
Abstract
Corrosion of medical implants is a possible failure mode via induced local inflammatory effects, systemic deposition and corrosion related mechanical failure. Cyclic potentiodynamic polarisation (CPP) testing was utilized to evaluate the effect of increased porosity (60% and 80%) and decreased wall thickness in [...] Read more.
Corrosion of medical implants is a possible failure mode via induced local inflammatory effects, systemic deposition and corrosion related mechanical failure. Cyclic potentiodynamic polarisation (CPP) testing was utilized to evaluate the effect of increased porosity (60% and 80%) and decreased wall thickness in gyroid lattice structures on the electrochemical behaviour of LPBF Ti6Al4V structures. The use of CPP allowed for the landmarks of breakdown potential, resting potential and vertex potential to be analysed, as well as facilitating the construction of Tafel plots and qualitative Goldberg analysis. The results indicated that 60% gyroid samples were most susceptible to the onset of pitting corrosion when compared to 80% gyroid and solid samples. This was shown through decreased breakdown and vertex potentials and were found to correlate to increased lattice surface area to void volume ratio. Tafel plots indicated that despite the earlier onset of pitting corrosion, both gyroid test groups displayed lower rates of corrosion per year, indicating a lower severity of corrosion. This study highlighted inherent tradeoffs between lattice optimisation and corrosion behaviour with a potential parabolic link between void volume, surface area and corrosion being identified. This potential link is supported by 60% gyroid samples having the lowest breakdown potentials, but investigation into other porosity ranges is suggested to support the hypothesis. All 3D printed materials studied here showed breakdown potentials higher than ASTM F2129′s suggestion of 800 mV for evaluation within the physiological environment, indicating that under static conditions pitting and crevice corrosion should not initiate within the body. Full article
(This article belongs to the Special Issue Corrosion in Additive Manufacturing)
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18 pages, 6539 KiB  
Article
Effect of Laser Speed and Hatch Spacing on the Corrosion Behavior of 316L Stainless Steel Produced by Selective Laser Melting
by Antonio Collazo, Raúl Figueroa, Carmen Pérez and Xosé Ramón Nóvoa
Materials 2022, 15(4), 1353; https://doi.org/10.3390/ma15041353 - 12 Feb 2022
Cited by 13 | Viewed by 2632
Abstract
In this work, the corrosion properties of 316L stainless steel (SS) obtained by selective laser melting (SLM) are analyzed. The electrochemical results of samples manufactured with an energy density between 40 and 140 J/mm3 are compared using different hatch distances and laser [...] Read more.
In this work, the corrosion properties of 316L stainless steel (SS) obtained by selective laser melting (SLM) are analyzed. The electrochemical results of samples manufactured with an energy density between 40 and 140 J/mm3 are compared using different hatch distances and laser speeds. The analysis correlates the impact of the microstructure and processing defects of SLM 316L stainless steel on its behavior against corrosion. The optimal manufacturing conditions were selected considering the electrochemical results. Although the samples obtained with an energy density close to 90 J/mm3 show a high resistance to corrosion, their performance depends on the combination of selected parameters, obtaining the best results for an intermediate laser speed and a low hatch distance. These manufacturing conditions produce a higher breakdown potential, a faster repassivation of the steel and reduce the current density on electrochemical test. Full article
(This article belongs to the Special Issue Corrosion in Additive Manufacturing)
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13 pages, 2867 KiB  
Article
Effect of Heat Treatment on Microstructure and Selective Corrosion of LPBF-AlSi10Mg by Means of SKPFM and Exo-Electron Emission
by Marina Cabrini, Sergio Lorenzi, Cristian Testa, Diego Manfredi, Mariangela Lombardi, Alberta Aversa, Francesco Andreatta, Lorenzo Fedrizzi, Yuri Dekhtyar, Hermanis Sorokins and Tommaso Pastore
Materials 2021, 14(19), 5602; https://doi.org/10.3390/ma14195602 - 27 Sep 2021
Cited by 6 | Viewed by 2304
Abstract
The paper deals with the evolution of the microstructure of AlSi10Mg alloy obtained by laser powder bed fusion (LPBF), as a function of the post-processing heat treatment temperature. This was approached by complementary methods including FE-scanning electron microscopy, scanning Kelvin probe force microscopy [...] Read more.
The paper deals with the evolution of the microstructure of AlSi10Mg alloy obtained by laser powder bed fusion (LPBF), as a function of the post-processing heat treatment temperature. This was approached by complementary methods including FE-scanning electron microscopy, scanning Kelvin probe force microscopy and exo-electron emission techniques. The fast cooling rate of the LPBF process as compared to traditional casting produces a very fine microstructure with high mechanical properties and corrosion resistance. However, the LPBF-AlSi10Mg alloy can be susceptible to selective corrosion at the edge of the melt pools generated by the laser scan tracks. Post-process thermal treatments of the Al alloy induce a marked modification of the silicon network at melt pool edges, in particular at high temperature such as 400 °C. It was found that this is associated to a more homogeneous distribution of Volta potential. Analysis of exo-electron emission confirms the silicon diffusion during thermal treatment. The modification of the silicon network structure of the LPBF-AlSi10Mg during thermal treatment reduces the susceptibility to selective corrosion. Full article
(This article belongs to the Special Issue Corrosion in Additive Manufacturing)
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