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<p>The increasing demand for corrosion-resistant and high-performance alloys in aerospace and marine applications requires surface engineering techniques to improve the lifetime of materials such as Inconel 625. This study examines the microstructural properties, coating integrity, and corrosion resistance of Inconel 625 alloy, manufactured via selective laser melting (SLM) and coated with plasma-sprayed Stellite 6. x-ray diffraction (XRD) examination validated the emergence of Co-based phases, signifying effective phase transformation and deposition throughout the coating procedure. Field emission scanning electron microscopy (FESEM) and atomic force microscopy (AFM) demonstrated a compact and homogeneous surface morphology with minimal surface imperfections. Energy-dispersive x-ray spectroscopy (EDS) and elemental mapping validated the uniform distribution of critical elements, including cobalt, oxygen, gadolinium, and cerium, recognized for their capacity to improve oxidation resistance. Electrochemical corrosion tests revealed enhanced passivation characteristics and diminished corrosion current density for the coated samples in comparison with uncoated Inconel 625. The incorporation of Stellite 6 through plasma spraying on SLM-processed Inconel 625 markedly enhances its corrosion resistance, hardness and microstructural stability, presenting favorable applicability in harsh and elevated-temperature service conditions.</p>

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Microstructural and Corrosion Behavior of Plasma-Sprayed Stellite 6-Coated Selective Laser Melting-Fabricated Inconel 625

  • 期刊论文

  • 发表日期：

    2025年9月23日

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  • Senthil Maharaj Kennedy,
  • R. B. Jeen Robert,
  • S. S. Sumesh,
  • S. Subramanian,
  • S. Vikash,
  • M. R. Vijayvel

摘要

The increasing demand for corrosion-resistant and high-performance alloys in aerospace and marine applications requires surface engineering techniques to improve the lifetime of materials such as Inconel 625. This study examines the microstructural properties, coating integrity, and corrosion resistance of Inconel 625 alloy, manufactured via selective laser melting (SLM) and coated with plasma-sprayed Stellite 6. x-ray diffraction (XRD) examination validated the emergence of Co-based phases, signifying effective phase transformation and deposition throughout the coating procedure. Field emission scanning electron microscopy (FESEM) and atomic force microscopy (AFM) demonstrated a compact and homogeneous surface morphology with minimal surface imperfections. Energy-dispersive x-ray spectroscopy (EDS) and elemental mapping validated the uniform distribution of critical elements, including cobalt, oxygen, gadolinium, and cerium, recognized for their capacity to improve oxidation resistance. Electrochemical corrosion tests revealed enhanced passivation characteristics and diminished corrosion current density for the coated samples in comparison with uncoated Inconel 625. The incorporation of Stellite 6 through plasma spraying on SLM-processed Inconel 625 markedly enhances its corrosion resistance, hardness and microstructural stability, presenting favorable applicability in harsh and elevated-temperature service conditions.