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<p>The Al5xxx series is widely utilized across industries due to its high strength and corrosion resistance relative to other aluminium alloy groups. However, high-strength aluminium alloys fabricated via Powder Bed Fusion-Laser Beam of Metals (PBF-LB/M) are prone to solidification cracking and manufacturing defects, such as porosity. Micro-alloying with tantalum (Ta) has emerged as a promising strategy to mitigate these issues, i.e. adding Ta to PBF-LB/M processed Al5254 alloy significantly refined the grain structure, reducing it from &gt; 100&#xa0;μm to ~ 10&#xa0;μm. This study evaluates the corrosion resistance of Al5254 and Ta-modified Al5254 processed via PBF-LB/M. Optimized processing parameters and novel chemical compositions were developed to minimize crack areas and porosity. Electrochemical performance was assessed in a 3.5% NaCl solution using linear polarization resistance (LPR) and Tafel extrapolation. Results indicate that Ta addition significantly enhances corrosion resistance by promoting self-passivation and altering the underlying corrosion mechanisms from intergranular corrosion to chemical passivation.</p>

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Corrosion behaviour of Al5254 alloy with tantalum addition processed by powder bed fusion–laser beam

  • 期刊论文

  • 发表日期：

    2026年3月8日

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  • Karol Kobiela,
  • Irina Smolina,
  • Konrad Gruber,
  • Wojciech Stopyra,
  • Michał Karoluk,
  • Jolanta Szczurek

摘要

The Al5xxx series is widely utilized across industries due to its high strength and corrosion resistance relative to other aluminium alloy groups. However, high-strength aluminium alloys fabricated via Powder Bed Fusion-Laser Beam of Metals (PBF-LB/M) are prone to solidification cracking and manufacturing defects, such as porosity. Micro-alloying with tantalum (Ta) has emerged as a promising strategy to mitigate these issues, i.e. adding Ta to PBF-LB/M processed Al5254 alloy significantly refined the grain structure, reducing it from > 100 μm to ~ 10 μm. This study evaluates the corrosion resistance of Al5254 and Ta-modified Al5254 processed via PBF-LB/M. Optimized processing parameters and novel chemical compositions were developed to minimize crack areas and porosity. Electrochemical performance was assessed in a 3.5% NaCl solution using linear polarization resistance (LPR) and Tafel extrapolation. Results indicate that Ta addition significantly enhances corrosion resistance by promoting self-passivation and altering the underlying corrosion mechanisms from intergranular corrosion to chemical passivation.