Effect of Direct Aging on Corrosion Behavior of AlSi10Mg Alloy Fabricated by Laser Powder Bed Fusion

doi:10.1007/s40195-023-01628-2

Abstract

Abstract:

Effect of direct aging of 170°C on corrosion behavior of laser powder bed fused AlSi10Mg (LPBF-AlSi10Mg) was studied by microstructure analysis, electrochemical analysis and X-ray photoelectron spectrometer. The results show that direct aging of 170 °C has little effect on melt pool and Si cellular structure, but promotes the precipitation of nano-Si particles and releases the residual stress. With increasing aging time from 0 to 4 h to 24 h, the corrosion property of the LPBF-AlSi10Mg is deteriorated, which is evidenced by increased corrosion current density and decreased pitting potential and polarization resistance. With increasing the aging time, the thickness of the oxide film formed on surface of the LPBF-AlSi10Mg increases. The Si content of the oxide film of the sample aging for 4 h is the lowest, 9.42 at.%, and it is the highest, 18.62 at.%, for the sample aging for 24 h. The electrochemical noise analysis reveals that the middle-frequency contribution of the Hilbert spectrum is responsible for the deteriorated corrosion performance, which corresponds to metastable pitting initiated by nano-Si particles.

Key words: Laser powder bed fusion, AlSi10Mg, Direct aging, Corrosion

Zhen Zhang, Zhanyong Zhao, Xiaofeng Li, Beibei Wang, Peikang Bai. Effect of Direct Aging on Corrosion Behavior of AlSi10Mg Alloy Fabricated by Laser Powder Bed Fusion[J]. Acta Metallurgica Sinica (English Letters), 2024, 37(2): 266-282.

Figures/Tables 19

Table 1 LPBF processing parameters

Power (W)	Speed (mm/s)	Hatch spacing (mm)	Slice thickness (mm)	Energy density (J/mm³)
370	1300	0.19	0.03	49.93

Fig. 1 Polished and etched morphologies of the LPBF-AlSi10Mg samples with different aging time: a and b DA0, c and d DA1, e and f DA2

Fig. 2 Typical SEM morphologies of the DA0 sample

Fig. 3 High magnification SEM morphologies of the three samples: a and b DA0, c and d DA1, e and f DA2

Fig. 4 Size and number density of the precipitates analyzed by the ImageJ software

Fig. 5 STEM morphologies and EDS mapping results of the cellular structure and the precipitates of the DA2 sample: a STEM morphology, b-d EDS mapping results, e and f EDS results of point 1 and point 2

Fig. 6 HRTEM images inside the cellular structure and the corresponding FFT/IFFT results of the DA2 sample

Fig. 7 Residual stress of three samples measured by using XRD

Fig. 8 a Representative polarization curves of the three samples in 3.5 wt% NaCl, b the cumulative probability distribution of the Epit

Fig. 9 Icorr a and Ecor b of the three samples in 3.5 wt% NaCl

Fig. 10 EIS results of the three samples in 3.5 wt% NaCl solution: a Nyquist plot, b Bode plot

Table 2 Fitting results of the EIS results

Samples	R_s (Ω cm²)	CPE₁ × 10^-6 (Ω⁻¹ cm⁻² s^-ⁿ)	n₁	R_f × 10³ (Ω cm²)	CPE₂ × 10^-5 (Ω⁻¹ cm⁻² s^-ⁿ)	n₂	R_ct × 10⁴ (Ω cm²)	O × 10^-4 (Ω⁻¹ cm⁻² s^−0.5)
DA0	6.43 ± 2.30	9.73 ± 0.54	0.93 ± 0.01	6.61 ± 1.65	1.48 ± 0.87	0.87 ± 0.15	6.56 ± 1.68	1.79 ± 0.87
DA1	9.51 ± 1.43	9.44 ± 0.38	0.94 ± 0.01	6.82 ± 1.35	2.23 ± 0.52	0.84 ± 0.23	4.12 ± 2.30	2.46 ± 0.69
DA2	11.48 ± 2.61	9.32 ± 0.24	0.93 ± 0.01	5.98 ± 0.87	2.36 ± 0.41	0.78 ± 0.19	3.87 ± 1.09	3.59 ± 0.34

Fig. 11 XPS results of the three samples after 24 h immersion in 3.5 wt% NaCl: a1-a3 survey spectrum, Al 2p and Si 2p of DA0, b1-b3 survey spectrum, Al 2p and Si 2p of DA1, c1-c3 survey spectrum, Al 2p and Si 2p of DA2

Fig. 12 EN results of the three samples in 3.5 wt% NaCl solution during the test period of 24 h: a DA0, b DA1, c DA2, d evolution of noise resistance

Fig. 13 Hilbert spectra of the three samples exposed to 3.5 wt% NaCl in 0-1 h and 23-24 h: a1-c1 DA0, DA1 and DA2 of 0-1 h; a2-c2 DA0, DA1 and DA2 of 23-24 h

Fig. 14 SEM morphologies of the three samples after soaking in 3.5 wt% NaCl solution for 24 h: a-c DA0, d-f DA1, g-i DA2

Fig. 15 SEM-EDS results of the pit for the DA0 sample

Fig. 16 SEM-EDS results of the pit for the DA1 sample

Fig. 17 Schematic diagram of corrosion mechanism of the three samples in 3.5 wt% NaCl solution

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