Correlation of LPBF process parameters and heat treatment with the corrosion behavior of AlSi10Mg alloy


Laieghi H., Butt M. M., Kvvssn V., Farooq A., Ansari P., SALAMCI M. U., ...More

Progress in Additive Manufacturing, vol.10, no.11, pp.10245-10264, 2025 (ESCI) identifier

  • Publication Type: Article / Article
  • Volume: 10 Issue: 11
  • Publication Date: 2025
  • Doi Number: 10.1007/s40964-025-01238-7
  • Journal Name: Progress in Additive Manufacturing
  • Journal Indexes: Emerging Sources Citation Index (ESCI), Scopus
  • Page Numbers: pp.10245-10264
  • Keywords: Additive manufacturing, AlSi10Mg, Corrosion, Defects, Heat treatment, Microstructure
  • Gazi University Affiliated: Yes

Abstract

This study investigates the corrosion resistance of LPBF-fabricated AlSi10Mg alloy, focusing on the interplay between process parameters and heat treatments. Volumetric energy densities ranging from 32 to 117 J/mm3 were employed, resulting in different microstructural features and defect types, including lack-of-fusion and keyhole pores. Electrochemical Impedance Spectroscopy (EIS) and Potentiodynamic Polarization (PDP) tests conducted in a 3.5 wt.% NaCl solution demonstrated that lower energy densities (< 78 J/mm3) exhibited improved corrosion resistance, while higher energy densities (≥ 78 J/mm3) led to accelerated corrosion. Stress-relief heat treatments were conducted on the samples with the best and worst corrosion resistance based on process parameters. Treatment at 200 °C had negligible impact on the silicon network and caused only a slight reduction in corrosion resistance, while treatment at 300 °C disrupted the silicon network near melt pool boundaries, leading to intensified selective corrosion.