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Microstructural and corrosion effects of HIP and chemically accelerated surface finishing on laser powder bed fusion Alloy 625

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Abstract

Hot isostatic pressing (HIP) and surface smoothing are two common post-processing methods to improve the mechanical properties of additively manufactured (AM) laser powder bed fusion (L-PBF) parts. While HIP increases part density and surface smoothing improves fatigue performance, it is unknown how, individually and together, these processes affect a component’s corrosion response. This study evaluated the resulting microstructures, surface roughness, and corrosion response of L-PBF Alloy 625 in the as-printed condition and after a standard HIP process to reduce porosity and after chemically accelerated vibratory finishing (CAVF) to improve surface finish. To assess any differences in build orientation, specimens evaluated were printed both vertically (Z-direction) and parallel (XY-direction) to the build platform. None of the specimens pitted during electrochemical evaluation, thus suggesting that the improved corrosion response of the CAVF specimens was due to a reduction in surface area. The Z-oriented as-printed specimen had significantly enhanced corrosion resistance due to a consistent distribution of alloying elements and a densely formed passive layer. Aside from the one exception, the results generally show HIP and CAVF result in minor impacts on the corrosion responses compared to as-printed L-PBF Alloy 625 despite differences in elemental distribution, surface morphology, and microstructural features. These post-processing methods may be employed to improve the mechanical properties of L-PBF Alloy 625 without concern of greatly altering the alloy’s inherently good corrosion properties.

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Abbreviations

AB:

As-built

AM:

Additive manufacturing

CAVF:

Chemically accelerated vibratory finishing

CMAF:

Chemically assisted magnetic abrasive finishing

CPP:

Cyclic potentiodynamic polarization

CS:

Combustion/IR detection

E corr :

Corrosion potential

EDS:

Energy-dispersive X-ray spectroscopy

E corr :

Passivation potential

GAS:

Inert gas fusion

HIP:

Hot isostatic pressing

i pass :

Passivation current

ISF:

Isotropic superfinishing

L-PBF:

Laser powder bed fusion

NH:

Non-HIP

OCP:

Open circuit potential

SEM:

Scanning electron microscope

SHE:

Standard hydrogen electrode

STEP:

Self-terminating etching process

XRF:

X-ray fluorescence

XRD:

X-ray diffraction

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Acknowledgements

The authors acknowledge the National Science Foundation for their generous financial support (NSF CAREER: 1944516). The authors would also like to thank and acknowledge REM Surface Engineering for performing the ISF® process on the specimens used in this work.

Funding

This material is based upon work supported by the National Science Foundation under Grant No. CAREER 1944516.

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Authors and Affiliations

  1. Materials Science Program, Colorado School of Mines, 1500 Illinois St, Golden, CO, 80401, USA

    Stephanie Prochaska

  2. Department of Mechanical Engineering, Colorado School of Mines, 1500 Illinois St, Golden, CO, 80401, USA

    Owen Hildreth

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  1. Stephanie Prochaska
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  2. Owen Hildreth
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All authors contributed to the study’s conception and design. Material preparation, data collection, and analysis were performed by Stephanie Prochaska. The first draft of the manuscript was written by Stephanie Prochaska, and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript. Funding resources and supervision were provided by Prof. Owen Hildreth.

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Correspondence to Owen Hildreth.

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Prochaska, S., Hildreth, O. Microstructural and corrosion effects of HIP and chemically accelerated surface finishing on laser powder bed fusion Alloy 625. Int J Adv Manuf Technol 121, 3759–3769 (2022). https://doi.org/10.1007/s00170-022-09579-1

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