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Elucidating the Effect of Build Location and Powder Morphology on the Corrosion of Selective Laser Sintered Additively Manufactured 316L Stainless Steel

Additive manufacturing (AM) has allowed for the rapid prototyping of parts and the ability to control the structure of a material and, to a lesser extent, the microstructure. AM as applied to metals, as stainless steel is especially promising as it provides the ability to produce complex shaped components rapidly. Laser-powder bed fusion (L-PBF) is one such technique in which the part is formed from the base up by fusing successive layers of powder. As each layer is fused, the print plate moves down and a new layer of metallic powder is swept over the top. A laser then welds this layer to the top of the existing piece and the process repeats.1 However, AM can result in non-equilibrium microstructures, porosity, and residual stresses that could affect the longevity of the material and performance in corrosive conditions.

Product Number: ED22-17456-SG
Author: E.Getto, E.Farnan, M.G. Koul, R.J. Santucci, T.Gray, J. S. Gibbs, J.McLaughlin
Publication Date: 2022
$20.00
$20.00
$20.00

Additive manufacturing (AM) offers exciting new advantages relevant to the US Department of Defense. The question remains as to what extent variation in location throughout the build influences the final properties of the built component. Further, the quality of the powder also affects build quality. These differences are anticipated to influence the final corrosion performance of the AM 316L builds in marine environments. 316L steel was printed using a Laser-Powder Bed Fusion system with normal powder and a treated powder that underwent a spheroidization process. Samples were taken from the top, middle and bottom segments of a vertically printed bar to assess the effect of quality on build location. Potentiodynamic testing indicated that the AM specimens were more resistant to pitting than the wrought material, and that the powder treatment process may result in material with a slightly higher resistance to pitting as indicated by a higher average breakdown potential compared to the material produced with normal powder. The porosity in the top and bottom samples was consistently higher than samples taken from the middle, indicating differing build quality as a function of position. The normal powder had a higher porosity than the treated, which was primarily due to a higher pore number density compared to those in the treated powder sample. Salt-water (0.6 M NaCl) exposures up to 20 weeks had minimum impact on the 316 builds, regardless of powder treatment or build location.

Additive manufacturing (AM) offers exciting new advantages relevant to the US Department of Defense. The question remains as to what extent variation in location throughout the build influences the final properties of the built component. Further, the quality of the powder also affects build quality. These differences are anticipated to influence the final corrosion performance of the AM 316L builds in marine environments. 316L steel was printed using a Laser-Powder Bed Fusion system with normal powder and a treated powder that underwent a spheroidization process. Samples were taken from the top, middle and bottom segments of a vertically printed bar to assess the effect of quality on build location. Potentiodynamic testing indicated that the AM specimens were more resistant to pitting than the wrought material, and that the powder treatment process may result in material with a slightly higher resistance to pitting as indicated by a higher average breakdown potential compared to the material produced with normal powder. The porosity in the top and bottom samples was consistently higher than samples taken from the middle, indicating differing build quality as a function of position. The normal powder had a higher porosity than the treated, which was primarily due to a higher pore number density compared to those in the treated powder sample. Salt-water (0.6 M NaCl) exposures up to 20 weeks had minimum impact on the 316 builds, regardless of powder treatment or build location.