Corrosion of Additive Manufactured Materials: An overview and Examples
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 are described and discussed - relating the corrosion performance to the microstructural features influenced by AM processing. 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. A number of examples are given, covering AM prepared steels, aluminium alloys and (even) magnesium alloys.
Nick Birbilis is a professor and deputy dean of the College of Engineering and Computer Science at the Australian National University (ANU) in Canberra, Australia. He earned a PhD in the Department of Materials Engineering at Monash University and undertook postdoctoral research at the Fontana Corrosion Center at The Ohio State University. Birbilis commenced his academic career at Monash University where he remained until 2018, before moving to the ANU. He has been active in a range of topics within the field of corrosion, and is known for his contributions in the areas of microstructure-corrosion relationships, particularly in Al and Mg alloy corrosion.