Martensitic stainless steel (MSS) has high hardness, mechanical strength, tribological performance, and corrosion resistance at milder temperatures. Additive manufacturing (AM) has brought industrial possibilities, such as customized geometries, on-demand production, and lead-time decrease. AM by laser directed energy deposition (L-DED) is intended for the building and repair of large parts. However, challenges arise due to the martensite brittleness and L-DED complex thermal history. Alternatively, lower C-content MSS can be used, as they offer a comparable property set with easier processability. In the L-DED, careful parameterization is required. There is still a dearth of literature regarding the L-DED processing of MSS for corrosion control. Within this context, the current study attempts to assess the corrosion resistance of a low C MSS (0.01 wt.%) multilayer samples built by AM L-DED AISI 410L in two parameterizations. Production (PRO), with a higher deposition rate, is meant for the building of bulker parts. Resolution (RES), with a lower deposition rate, is meant for more complex geometries. Two L-DED experiments were performed, one for PRO and the other for RES. Standardized multilayer samples were built in an argon-controlled atmosphere to mitigate the insertion of oxygen and impurities. Archimedes’ density, microstructure, hardness, and electrochemical corrosion by potentiodynamic polarization in a 3.5% NaCl solution at room temperature analyses were performed. Samples of a commercial hot-rolled and annealed 410 MSS with a higher C-content (0.15 wt.%) were used as reference material (410-REF). Results showed compatible density levels (99.95%) in both L-DED optimized parametrizations. The L-DED microstructure obtained was biphasic with ferrite and refined martensite laths concentrated at the grain boundaries, owing to the laser fast cooling and AISI 410L lower C-content. The RES parameter produced a more refined microstructure, with a larger grain boundary area and 7% higher hardness than the PRO one, due to the faster solidification of the first condition. The 410-REF, in turn, showed a coarse ferrite plus tempered martensite and Cr-carbides, with a significantly lower hardness regarding both L-DED conditions. Electrochemical test data revealed a more positive corrosion potential Ecorr and a lower corrosion current Icorr for the RES parameter, which suggests a more effective passivation of this regarding the L-DED PRO and 410-REF. This indicates that lower C-content AISI 410L processed by L-DED at lower energy densities will be more resistant to corrosion in the presence of chlorides.

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Corrosion Performance of AISI 410L Martensitic Stainless Steel Parts Manufactured by Laser Directed Energy Deposition in Different Parametrizations

  • Jurandir Marcos Sá de Sousa,
  • Milton Pereira,
  • Bruno Borges Ramos,
  • Cristiano Binder,
  • Juliana Ribeiro da Cruz

摘要

Martensitic stainless steel (MSS) has high hardness, mechanical strength, tribological performance, and corrosion resistance at milder temperatures. Additive manufacturing (AM) has brought industrial possibilities, such as customized geometries, on-demand production, and lead-time decrease. AM by laser directed energy deposition (L-DED) is intended for the building and repair of large parts. However, challenges arise due to the martensite brittleness and L-DED complex thermal history. Alternatively, lower C-content MSS can be used, as they offer a comparable property set with easier processability. In the L-DED, careful parameterization is required. There is still a dearth of literature regarding the L-DED processing of MSS for corrosion control. Within this context, the current study attempts to assess the corrosion resistance of a low C MSS (0.01 wt.%) multilayer samples built by AM L-DED AISI 410L in two parameterizations. Production (PRO), with a higher deposition rate, is meant for the building of bulker parts. Resolution (RES), with a lower deposition rate, is meant for more complex geometries. Two L-DED experiments were performed, one for PRO and the other for RES. Standardized multilayer samples were built in an argon-controlled atmosphere to mitigate the insertion of oxygen and impurities. Archimedes’ density, microstructure, hardness, and electrochemical corrosion by potentiodynamic polarization in a 3.5% NaCl solution at room temperature analyses were performed. Samples of a commercial hot-rolled and annealed 410 MSS with a higher C-content (0.15 wt.%) were used as reference material (410-REF). Results showed compatible density levels (99.95%) in both L-DED optimized parametrizations. The L-DED microstructure obtained was biphasic with ferrite and refined martensite laths concentrated at the grain boundaries, owing to the laser fast cooling and AISI 410L lower C-content. The RES parameter produced a more refined microstructure, with a larger grain boundary area and 7% higher hardness than the PRO one, due to the faster solidification of the first condition. The 410-REF, in turn, showed a coarse ferrite plus tempered martensite and Cr-carbides, with a significantly lower hardness regarding both L-DED conditions. Electrochemical test data revealed a more positive corrosion potential Ecorr and a lower corrosion current Icorr for the RES parameter, which suggests a more effective passivation of this regarding the L-DED PRO and 410-REF. This indicates that lower C-content AISI 410L processed by L-DED at lower energy densities will be more resistant to corrosion in the presence of chlorides.