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Laser-Based Additive Manufacturing and Mechanical Surface Post-Processing: Comparison of Barrel Finishing, Shot and Ultrasonic Peening for Corrosion Resistance Improvement of Superalloy

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Abstract

Nickel-based alloy test parts were manufactured using an industrial laser 3D printing system. The corrosion behavior of the laser powder bed fused (LPBF) Inconel 718 alloy parts are analyzed in as-built and mechanical surface post-processed conditions, i.e. after barrel finishing, shot peening, ultrasonic shot peening, and multi-pin ultrasonic impact treatment. The microstructural features are analyzed using the X-Ray diffraction (XRD) analysis and scanning electron microscopy (SEM) / energy dispersive spectroscopy (EDS) methods. The open circuit potential and linear/cyclic polarization were registered in a 3.5 wt.% NaCl solution. The surface roughness diminishment, defects elimination, residual pores’ closure, as well as the residual stress and structure-phase state changes were under special attention. The polarization resistance, corrosion current density, corrosion rate, pitting initiation rate, anodic dissolution, ability for repassivation, and crevice corrosion resistance were assessed and compared.

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Data Availability

The dataset generated and analyzed during the current study are available from the corresponding author on reasonable request.

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Acknowledgements

The authors would like to thank O. Stamann and S. Faust (Otto von Guericke University Magdeburg, Germany) for the support provided with the surface morphology and roughness measurements.

Funding

This work was supported by the National Research Foundation of Ukraine (NRFU) for the support of the Project within the NRFU Competition ‘Science for the Recovery of Ukraine in the War and Post-War Periods’ (Grant number 2022.01/0038). Mordyuk B.M. and Lesyk D.A. have received research support from NRFU. D.A. Lesyk is also grateful to the Ulam NAWA and ADAGIO Post-doctoral Fellowship Research Programs.

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Authors and Affiliations

  1. Laser Systems and Advanced Technologies Department, National Technical University of Ukraine “Igor Sikorsky Kyiv Polytechnic Institute”, 37 Prospect Beresteiskyi, Kyiv, 03056, Ukraine

    D. A. Lesyk & V. V. Dzhemelinskyi

  2. Physical Principles for Surface Engineering Department, Kurdyumov Institute for Metal Physics of the NAS of Ukraine, 36 Academician Vernadsky Blvd., Kyiv, 03142, Ukraine

    D. A. Lesyk & B. N. Mordyuk

  3. Aeronautics Advanced Manufacturing Center, University of the Basque Country, 202 Bizkaia Science and Technology Park, 48170, Zamudio, Spain

    D. A. Lesyk, S. Martinez & A. Lamikiz

  4. Mechanical Engineering and Mechatronics Department, West Pomeranian University of Technology, 17 Aleja Piastow, 70310, Szczecin, Poland

    D. Grzesiak & D. Grochała

  5. Mechanical Engineering Department, University of the Basque Country, Alameda Urquijo S/N, 48013, Bilbao, Spain

    A. Lamikiz

Authors
  1. D. A. Lesyk
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  2. B. N. Mordyuk
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  3. S. Martinez
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  4. V. V. Dzhemelinskyi
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  5. D. Grzesiak
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  6. D. Grochała
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  7. A. Lamikiz
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Contributions

All authors contributed to the study conception and design. Material preparation, data collection and analysis were performed by Dmytro Lesyk, Bohdan Mordyuk, and Silvia Martinez. The first draft of the manuscript was written by Dmytro Lesyk and Bohdan Mordyuk and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to D. A. Lesyk or B. N. Mordyuk.

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Lesyk, D.A., Mordyuk, B.N., Martinez, S. et al. Laser-Based Additive Manufacturing and Mechanical Surface Post-Processing: Comparison of Barrel Finishing, Shot and Ultrasonic Peening for Corrosion Resistance Improvement of Superalloy. Lasers Manuf. Mater. Process. 10, 702–734 (2023). https://doi.org/10.1007/s40516-023-00231-8

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