Machine-to-machine variability of roughness and corrosion in additively manufactured 316L stainless steel

Clark, C. L.; Karasz, E. K.; Melia, M.; Hooks, D. E.; Hackenberg, R.; Colon-Mercado, H.; Ganesan, P.; Renner, P.; Cho, S.; Wu, M.; Qiu, S. R.; Dwyer, J.; Rueger, Z.; Gorey, T. J.; Koehn, Z.; Stull, J. A.

doi:10.1016/j.jmapro.2023.09.059

Machine-to-machine variability of roughness and corrosion in additively manufactured 316L stainless steel

Journal Article · Thu Oct 12 00:00:00 EDT 2023 · Journal of Manufacturing Processes

DOI:https://doi.org/10.1016/j.jmapro.2023.09.059· OSTI ID:2198538

Clark, C. L. ^[1]; Karasz, E. K. ^[2]; Melia, M. ^[2]; Hooks, D. E. ^[1]; Hackenberg, R. ^[1]; Colon-Mercado, H. ^[3]; Ganesan, P. ^[3]; Renner, P. ^[2]; Cho, S. ^[4]; Wu, M. ^[4]; Qiu, S. R. ^[4]; Dwyer, J. ^[5]; Rueger, Z. ^[5]; Gorey, T. J. ^[1]; Koehn, Z. ^[1]; Stull, J. A. ^[1]

Los Alamos National Laboratory (LANL), Los Alamos, NM (United States)
Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)
Savannah River National Laboratory (SRNL), Aiken, SC (United States)
Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)
Kansas City National Security Campus (KCNSC), Kansas City, MO (United States)

Numerous studies on the corrosion response of metal AM have been conducted. Nonetheless, the specimens being tested are commonly ground or polished to remove the outer as-built surface. If metal AM is truly going to be employed as a transformative technology that can produce complex shapes that do not require traditional machining, then the material needs to be evaluated in the as-built state. The reality is that AM alloys have shown significant inconsistencies regarding as-built surface texture, topology, and residual stress. One metric that has shown significant unpredictability in the literature is the susceptibility to localized corrosion of typically passive alloys, such as stainless steel (SS). There are a large number of studies that have attempted to understand the corrosion response of metal AM materials, but these studies are typically performed on materials that have been printed on a single machine and often mechanically polished to a smooth finish. This study compares the corrosion response of as-built AM, laser-beam powder bed fusion (LB-PBF), 316L SS parts that have been fabricated on five different machines. The majority of this work focused on understanding the susceptibility to localized corrosion of AM metals with respect to machine-dependent variables, namely surface roughness, and build angle. Surface roughness data was collected using scanning white light triangulation, laser scanning confocal microscopy, and coherence scanning interferometry. The results show that there is significant variability (p_two-tail< 0.05) in the susceptibility to local corrosion initiation of LB-PBF 316L SS samples built on different machines. Surface oxides were probed with electron dispersive spectroscopy and revealed that variations in local corrosion susceptibility likely arise from differences in the stability of the passive film caused by chemical segregation, unique microstructure, and tortuous roughness features at the as-built surfaces. The variability of roughness and corrosion properties from test samples printed on different machines was corroborated by property measurements performed at five different testing sites, proving reproducibility of the data. Most importantly, this study shows that if the as-built surface layer is removed through grinding or electropolishing the machine-to-machine variation observed in the corrosion susceptibility is reduced.

View Accepted Manuscript (DOE)

Research Organization:: Kansas City Nuclear Security Campus (KCNSC), Kansas City, MO (United States); Los Alamos National Laboratory (LANL), Los Alamos, NM (United States). Center for Integrated Nanotechnologies (CINT); Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States); Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)

Sponsoring Organization:: USDOE National Nuclear Security Administration (NNSA); USDOE Office of Science (SC)

Grant/Contract Number:: NA0002839; 89233218CNA000001; 89303321CEM000080; NA0003525; AC52-07NA27344

OSTI ID:: 2198538

Alternate ID(s):: OSTI ID: 2316042
OSTI ID: 2203416

Report Number(s):: NSC--614-4960

Journal Information:: Journal of Manufacturing Processes, Journal Name: Journal of Manufacturing Processes Vol. 106; ISSN 1526-6125

Publisher:: Society of Manufacturing Engineers; ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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