Pitting Corrosion in 316L Stainless Steel Fabricated by Laser Powder Bed Fusion Additive Manufacturing: A Review and Perspective

Voisin, T.; Shi, R.; Zhu, Y.; Qi, Z.; Wu, M.; Sen-Britain, S.; Zhang, Y.; Qiu, S. R.; Wang, Y. M.; Thomas, S.; Wood, B. C.

doi:10.1007/s11837-022-05206-2

Title: Pitting Corrosion in 316L Stainless Steel Fabricated by Laser Powder Bed Fusion Additive Manufacturing: A Review and Perspective

Abstract

Abstract 316L stainless steel (316L SS) is a flagship material for structural applications in corrosive environments, having been extensively studied for decades for its favorable balance between mechanical and corrosion properties. More recently, 316L SS has also proven to have excellent printability when parts are produced with additive manufacturing techniques, notably laser powder bed fusion (LPBF). Because of the harsh thermo-mechanical cycles experienced during rapid solidification and cooling, LPBF processing tends to generate unique microstructures. Strong heterogeneities can be found inside grains, including trapped elements, nano-inclusions, and a high density of dislocations that form the so-called cellular structure. Interestingly, LPBF 316L SS not only exhibits better mechanical properties than its conventionally processed counterpart, but it also usually offers much higher resistance to pitting in chloride solutions. Unfortunately, the complexity of the LPBF microstructures, in addition to process-induced defects, such as porosity and surface roughness, have slowed progress toward linking specific microstructural features to corrosion susceptibility and complicated the development of calibrated simulations of pitting phenomena. The first part of this article is dedicated to an in-depth review of the microstructures found in LPBF 316L SS and their potential effects on the corrosion properties, with an emphasis on pitting resistance. Themore »« less

Authors:

; Shi, R.; Zhu, Y.; Qi, Z.; Wu, M.; Sen-Britain, S.; Zhang, Y.; Qiu, S. R.; Wang, Y. M.; Thomas, S.; Wood, B. C.

Publication Date:: Mon Mar 07 00:00:00 EST 2022

Sponsoring Org.:: USDOE

OSTI Identifier:: 1847990

Grant/Contract Number:: 20-SI-04; AC52-07NA27344

Resource Type:: Published Article

Journal Name:: JOM. Journal of the Minerals, Metals & Materials Society

Additional Journal Information:: Journal Name: JOM. Journal of the Minerals, Metals & Materials Society Journal Volume: 74 Journal Issue: 4; Journal ID: ISSN 1047-4838

Publisher:: Springer Science + Business Media

Country of Publication:: United States

Language:: English

Citation Formats


                    Voisin, T., Shi, R., Zhu, Y., Qi, Z., Wu, M., Sen-Britain, S., Zhang, Y., Qiu, S. R., Wang, Y. M., Thomas, S., and Wood, B. C. Pitting Corrosion in 316L Stainless Steel Fabricated by Laser Powder Bed Fusion Additive Manufacturing: A Review and Perspective.  United States: N. p., 2022. 
Web.  doi:10.1007/s11837-022-05206-2.

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                    Voisin, T., Shi, R., Zhu, Y., Qi, Z., Wu, M., Sen-Britain, S., Zhang, Y., Qiu, S. R., Wang, Y. M., Thomas, S., & Wood, B. C. Pitting Corrosion in 316L Stainless Steel Fabricated by Laser Powder Bed Fusion Additive Manufacturing: A Review and Perspective.  United States.  https://doi.org/10.1007/s11837-022-05206-2

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                    Voisin, T., Shi, R., Zhu, Y., Qi, Z., Wu, M., Sen-Britain, S., Zhang, Y., Qiu, S. R., Wang, Y. M., Thomas, S., and Wood, B. C. Mon .  
"Pitting Corrosion in 316L Stainless Steel Fabricated by Laser Powder Bed Fusion Additive Manufacturing: A Review and Perspective".  United States.  https://doi.org/10.1007/s11837-022-05206-2.

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@article{osti_1847990,

  title        = {Pitting Corrosion in 316L Stainless Steel Fabricated by Laser Powder Bed Fusion Additive Manufacturing: A Review and Perspective},

  author       = {Voisin, T. and Shi, R. and Zhu, Y. and Qi, Z. and Wu, M. and Sen-Britain, S. and Zhang, Y. and Qiu, S. R. and Wang, Y. M. and Thomas, S. and Wood, B. C.},

  abstractNote = {Abstract 316L stainless steel (316L SS) is a flagship material for structural applications in corrosive environments, having been extensively studied for decades for its favorable balance between mechanical and corrosion properties. More recently, 316L SS has also proven to have excellent printability when parts are produced with additive manufacturing techniques, notably laser powder bed fusion (LPBF). Because of the harsh thermo-mechanical cycles experienced during rapid solidification and cooling, LPBF processing tends to generate unique microstructures. Strong heterogeneities can be found inside grains, including trapped elements, nano-inclusions, and a high density of dislocations that form the so-called cellular structure. Interestingly, LPBF 316L SS not only exhibits better mechanical properties than its conventionally processed counterpart, but it also usually offers much higher resistance to pitting in chloride solutions. Unfortunately, the complexity of the LPBF microstructures, in addition to process-induced defects, such as porosity and surface roughness, have slowed progress toward linking specific microstructural features to corrosion susceptibility and complicated the development of calibrated simulations of pitting phenomena. The first part of this article is dedicated to an in-depth review of the microstructures found in LPBF 316L SS and their potential effects on the corrosion properties, with an emphasis on pitting resistance. The second part offers a perspective of some relevant modeling techniques available to simulate the corrosion of LPBF 316L SS, including current challenges that should be overcome.},

  doi          = {10.1007/s11837-022-05206-2},

  journal      = {JOM. Journal of the Minerals, Metals & Materials Society},

  number       = 4,

  volume       = 74,

  place        = {United States},

  year         = {Mon Mar 07 00:00:00 EST 2022},

  month        = {Mon Mar 07 00:00:00 EST 2022}

}

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Journal Article Cho, Seongkoo ; Buchsbaum, Steven F. ; Biener, Monika ; ... - Materials & Design

Laser powder bed fusion (LPBF) additively manufactured (AM) 316L stainless steels (SS) possess much more complex surfaces than their wrought counterparts which affects the corrosion behavior. Surface roughness, a typical metric for assessing corrosion of conventionally manufactured metals, is often ineffective as an independent parameter in characterizing corrosion of the AM metals for their higher surface roughness ranging from 5 to 50 µm. This study experimentally shows that the true active surface area (A_TA) is a proper parameter for quick assessment of localized corrosion response of AM 316L SS. Through the potentiodynamic polarization testing on surrogates under full immersion in 0.6 M NaCl solution, the pitting corrosion susceptibility was evaluated. While no consistent correlation to surface roughness was displayed, the pitting breakdown potential (E_p) showed a clear statistical trend atmore »« less
https://doi.org/10.1016/j.matdes.2023.112559
Effects of laser surface melting on the pitting resistance of sensitized nitrogen-bearing type 316L stainless steel

Journal Article Kamachi Mudali, U ; Pujar, M G ; Dayal, R K - Journal of Materials Engineering and Performance

Austenitic stainless steels (SS) form a major part of the structural materials for fast reactors because of their excellent mechanical properties at high temperatures and good corrosion resistance in general. Here, laser surface melting of sensitized nitrogen-bearing type 316L austenitic stainless steel was carried out using a pulsed ruby laser. The sensitization heat treatment was carried out at 923 K for 50, 200, 1,000, and 2,500 h, and the sensitized microstructure was classified according to ASTM A 262 practice A. The degree of sensitization was assessed by the electrochemical potentiokinetic reactivation (EPR) test. The critical pitting potentials of as-sensitized asmore »« less
https://doi.org/10.1361/105994998770347945
Mechanical Properties and Deformation Behavior of Additively Manufactured 316L Stainless Steel (FY2020)

Technical Report Byun, T. S. ; Gussev, Maxim N. ; Lach, Tim G. ; ...

The Transformational Challenge Reactor (TCR) program plans to build most of the TCR core components through additive manufacturing (AM) processes. These processes include laser powder bed fusion (LPBF) for the metallic (316L) components and the newly developed combined process of binderjet printing and chemical vapor infiltration (CVI) for the SiC fuel matrix. Mechanical testing and characterization tasks have been carried out since the beginning of the TCR program to (1) build a property database for the AM materials that will be used in TCR core and (2) to assess the materials’ performance in TCR-relevant conditions. This document reports the outcomemore »« less
https://doi.org/10.2172/1649091

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Title: Pitting Corrosion in 316L Stainless Steel Fabricated by Laser Powder Bed Fusion Additive Manufacturing: A Review and Perspective

Abstract

Citation Formats

Numerical modeling of corrosion pit propagation using the combined extended finite element and level set method journal, April 2014

Microstructure Generation via Generative Adversarial Network for Heterogeneous, Topologically Complex 3D Materials journal, December 2020

The Use of Finite Element Methods (FEM) in the Modeling of Localized Corrosion journal, January 2014

Tracking the evolution of intergranular corrosion through twin-related domains in grain boundary networks journal, April 2018

On the limitations of Volumetric Energy Density as a design parameter for Selective Laser Melting journal, January 2017

Transformation of austenite to duplex austenite-ferrite assembly in annealed stainless steel 316L consolidated by laser melting journal, June 2015

A cellular automaton model for predicting intergranular corrosion journal, August 2011

Selective Laser Melting of Copper journal, February 2016

Effect of atomization on surface oxide composition in 316L stainless steel powders for additive manufacturing journal, June 2020

Controlling interdependent meso-nanosecond dynamics and defect generation in metal 3D printing journal, May 2020

A Point Defect Model for Anodic Passive Films journal, January 1981

Phase field modeling of simultaneous nucleation and growth by explicitly incorporating nucleation events journal, October 2000

Characteristics of Mechanical Properties and Microstructure for 316L Austenitic Stainless Steel journal, November 2011

Observation of keyhole-mode laser melting in laser powder-bed fusion additive manufacturing journal, December 2014

A mesoscopic digital twin that bridges length and time scales for control of additively manufactured metal microstructures journal, June 2021

Pitting corrosion behaviour of austenitic stainless steels – combining effects of Mn and Mo additions journal, June 2008

Improvement of Pitting Corrosion Resistance of Type 316L Stainless Steel by Potentiostatic Removal of Surface MnS Inclusions journal, January 2012

Anomalous evolution of corrosion behaviour of warm-rolled type 304 austenitic stainless steel journal, July 2019

Corrosion-passivation processes in a cellular automata based simulation study journal, April 2013

Dislocation network in additive manufactured steel breaks strength–ductility trade-off journal, May 2018

Corrosion behaviour of 316L stainless steel and anti-corrosion materials in a high acidified chloride solution journal, December 2014

Investigation of effects of process parameters on microstructure and hardness of SLM manufactured SS316L journal, April 2018

Critical pitting temperature of selective laser melted 316L stainless steel: A mechanistic approach journal, June 2021

On the effect of build orientation and residual stress on the corrosion of 316L stainless steel prepared by selective laser melting journal, February 2021

A Review of the Application of Finite Element Method (FEM) to Localized Corrosion Modeling journal, September 2019

Theoretical and experimental studies of the pitting of type 316L stainless steel in borate buffer solution containing nitrate ion journal, January 2007

Electrochemical studies on the effect of residual stress on the corrosion of 316L manufactured by selective laser melting journal, March 2020

Density of additively-manufactured, 316L SS parts using laser powder-bed fusion at powers up to 400 W journal, May 2014

DREAM.3D: A Digital Representation Environment for the Analysis of Microstructure in 3D journal, April 2014

Corrosion of Additively Manufactured Alloys: A Review journal, October 2018

Residual Stress in Metal Additive Manufacturing journal, January 2018

New phase field model for simulating galvanic and pitting corrosion processes journal, January 2018

Microstructure and Corrosion Resistance of Laser Additively Manufactured 316L Stainless Steel journal, February 2016

Multiscale Modeling of Powder Bed–Based Additive Manufacturing journal, July 2016

Effect of the powder feedstock on the oxide dispersion strengthening of 316L stainless steel produced by laser powder bed fusion journal, November 2020

On The Corrosion and Metastable Pitting Characteristics of 316L Stainless Steel Produced by Selective Laser Melting journal, January 2017

Selective laser melting (SLM) of AISI 316L—impact of laser power, layer thickness, and hatch spacing on roughness, density, and microhardness at constant input energy density journal, May 2020

Phase-field modeling of bimodal particle size distributions during continuous cooling journal, February 2003

Anisotropy in mechanical properties and corrosion resistance of 316L stainless steel fabricated by selective laser melting journal, March 2019

Effect of grain size on pitting corrosion of 304L austenitic stainless steel journal, May 2015

Effect of grain size on the corrosion resistance of low carbon steel journal, January 2020

Corrosion of metallic materials fabricated by selective laser melting journal, June 2019

The significance of spatial length scales and solute segregation in strengthening rapid solidification microstructures of 316L stainless steel journal, February 2020

Effect of texture on corrosion behavior of AISI 304L stainless steel journal, February 2005

Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges journal, December 2015

High Strength and Ductility of Additively Manufactured 316L Stainless Steel Explained journal, April 2018

On the first breakdown in AA7075-T6 journal, July 2007

Diagrams for laser materials processing journal, July 1992

Phase-field modeling for pH-dependent general and pitting corrosion of iron journal, August 2018

Perforated Covers for Propagating Pits journal, January 1998

Process defects and in situ monitoring methods in metal powder bed fusion: a review journal, February 2017

EIS comparative study and critical Equivalent Electrical Circuit (EEC) analysis of the native oxide layer of additive manufactured and wrought 316L stainless steel journal, May 2020

The Effect of Surface Roughness on the Corrosion Properties of Type AISI 304 Stainless Steel in Diluted NaCl and Urban Rain Solution journal, March 2014

Effect of process parameters for selective laser melting with SUS316L on mechanical and microstructural properties with variation in chemical composition journal, January 2021

Solute trapping in rapid solidification journal, November 2020

Studies of the initiation of pitting corrosion on stainless steels journal, December 1984

A new TriBeam system for three-dimensional multimodal materials analysis journal, February 2012

The nucleation, growth and stability of micropits in stainless steel journal, July 1994

Effect of grain refinement and electrochemical nitridation on corrosion resistance of the 316L stainless steel for bipolar plates in PEMFCs environment journal, October 2015

Effect of surface roughness on early stages of pitting corrosion of Type 301 stainless steel journal, September 1997

Computational simulation of metastable pitting of stainless steel journal, November 2009

First-principles modeling of anisotropic anodic dissolution of metals and alloys in corrosive environments journal, May 2017

Microstructure and corrosion behavior of 316L stainless steel prepared using different additive manufacturing methods: A comparative study bringing insights into the impact of microstructure on their passivity journal, November 2020

Why stainless steel corrodes journal, February 2002

Modulation of dendritic patterns during electrodeposition: A nonlinear phase-field model journal, December 2015

Microstructure and Fracture Behavior of 316L Austenitic Stainless Steel Produced by Selective Laser Melting journal, August 2016

Modeling the effect of insoluble corrosion products on pitting corrosion kinetics of metals journal, July 2019

Controlling grain nucleation and morphology by laser beam shaping in metal additive manufacturing journal, October 2020

An alternate explanation for the abrupt current increase at the pitting potential journal, February 2008

Additively manufactured hierarchical stainless steels with high strength and ductility journal, October 2017

Viewpoint: metallurgical aspects of powder bed metal additive manufacturing journal, November 2015

Corrosion of Binder Jetting Additively Manufactured 316L Stainless Steel of Different Surface Finish journal, January 2020

Correlation between process parameters, microstructure and properties of 316 L stainless steel processed by selective laser melting journal, March 2018

Influence of scanning strategy and building direction on microstructure and corrosion behaviour of selective laser melted 316L stainless steel journal, November 2021

Quantitative multiscale correlative microstructure analysis of additive manufacturing of stainless steel 316L processed by selective laser melting journal, February 2020

The passivity of selective laser melted 316L stainless steel journal, February 2020

Processing parameters in laser powder bed fusion metal additive manufacturing journal, August 2020

Numerical modeling of corrosion pit propagation using the combined extended finite element and level set method
journal, April 2014

Microstructure Generation via Generative Adversarial Network for Heterogeneous, Topologically Complex 3D Materials
journal, December 2020

The Use of Finite Element Methods (FEM) in the Modeling of Localized Corrosion
journal, January 2014

Tracking the evolution of intergranular corrosion through twin-related domains in grain boundary networks
journal, April 2018

On the limitations of Volumetric Energy Density as a design parameter for Selective Laser Melting
journal, January 2017

Transformation of austenite to duplex austenite-ferrite assembly in annealed stainless steel 316L consolidated by laser melting
journal, June 2015

A cellular automaton model for predicting intergranular corrosion
journal, August 2011

Selective Laser Melting of Copper
journal, February 2016

Effect of atomization on surface oxide composition in 316L stainless steel powders for additive manufacturing
journal, June 2020

Controlling interdependent meso-nanosecond dynamics and defect generation in metal 3D printing
journal, May 2020

A Point Defect Model for Anodic Passive Films
journal, January 1981

Phase field modeling of simultaneous nucleation and growth by explicitly incorporating nucleation events
journal, October 2000

Characteristics of Mechanical Properties and Microstructure for 316L Austenitic Stainless Steel
journal, November 2011

Observation of keyhole-mode laser melting in laser powder-bed fusion additive manufacturing
journal, December 2014

A mesoscopic digital twin that bridges length and time scales for control of additively manufactured metal microstructures
journal, June 2021

Pitting corrosion behaviour of austenitic stainless steels – combining effects of Mn and Mo additions
journal, June 2008

Improvement of Pitting Corrosion Resistance of Type 316L Stainless Steel by Potentiostatic Removal of Surface MnS Inclusions
journal, January 2012

Anomalous evolution of corrosion behaviour of warm-rolled type 304 austenitic stainless steel
journal, July 2019

Corrosion-passivation processes in a cellular automata based simulation study
journal, April 2013

Dislocation network in additive manufactured steel breaks strength–ductility trade-off
journal, May 2018

Corrosion behaviour of 316L stainless steel and anti-corrosion materials in a high acidified chloride solution
journal, December 2014

Investigation of effects of process parameters on microstructure and hardness of SLM manufactured SS316L
journal, April 2018

Critical pitting temperature of selective laser melted 316L stainless steel: A mechanistic approach
journal, June 2021

On the effect of build orientation and residual stress on the corrosion of 316L stainless steel prepared by selective laser melting
journal, February 2021

A Review of the Application of Finite Element Method (FEM) to Localized Corrosion Modeling
journal, September 2019

Theoretical and experimental studies of the pitting of type 316L stainless steel in borate buffer solution containing nitrate ion
journal, January 2007

Electrochemical studies on the effect of residual stress on the corrosion of 316L manufactured by selective laser melting
journal, March 2020

Density of additively-manufactured, 316L SS parts using laser powder-bed fusion at powers up to 400 W
journal, May 2014

DREAM.3D: A Digital Representation Environment for the Analysis of Microstructure in 3D
journal, April 2014

Corrosion of Additively Manufactured Alloys: A Review
journal, October 2018

Residual Stress in Metal Additive Manufacturing
journal, January 2018

New phase field model for simulating galvanic and pitting corrosion processes
journal, January 2018

Microstructure and Corrosion Resistance of Laser Additively Manufactured 316L Stainless Steel
journal, February 2016

Multiscale Modeling of Powder Bed–Based Additive Manufacturing
journal, July 2016

Effect of the powder feedstock on the oxide dispersion strengthening of 316L stainless steel produced by laser powder bed fusion
journal, November 2020

On The Corrosion and Metastable Pitting Characteristics of 316L Stainless Steel Produced by Selective Laser Melting
journal, January 2017

Selective laser melting (SLM) of AISI 316L—impact of laser power, layer thickness, and hatch spacing on roughness, density, and microhardness at constant input energy density
journal, May 2020

Phase-field modeling of bimodal particle size distributions during continuous cooling
journal, February 2003

Anisotropy in mechanical properties and corrosion resistance of 316L stainless steel fabricated by selective laser melting
journal, March 2019

Effect of grain size on pitting corrosion of 304L austenitic stainless steel
journal, May 2015

Effect of grain size on the corrosion resistance of low carbon steel
journal, January 2020

Corrosion of metallic materials fabricated by selective laser melting
journal, June 2019

The significance of spatial length scales and solute segregation in strengthening rapid solidification microstructures of 316L stainless steel
journal, February 2020

Effect of texture on corrosion behavior of AISI 304L stainless steel
journal, February 2005

Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges
journal, December 2015

High Strength and Ductility of Additively Manufactured 316L Stainless Steel Explained
journal, April 2018

On the first breakdown in AA7075-T6
journal, July 2007

Diagrams for laser materials processing
journal, July 1992

Phase-field modeling for pH-dependent general and pitting corrosion of iron
journal, August 2018

Perforated Covers for Propagating Pits
journal, January 1998

Process defects and in situ monitoring methods in metal powder bed fusion: a review
journal, February 2017

EIS comparative study and critical Equivalent Electrical Circuit (EEC) analysis of the native oxide layer of additive manufactured and wrought 316L stainless steel
journal, May 2020

The Effect of Surface Roughness on the Corrosion Properties of Type AISI 304 Stainless Steel in Diluted NaCl and Urban Rain Solution
journal, March 2014

Effect of process parameters for selective laser melting with SUS316L on mechanical and microstructural properties with variation in chemical composition
journal, January 2021

Solute trapping in rapid solidification
journal, November 2020

Studies of the initiation of pitting corrosion on stainless steels
journal, December 1984

A new TriBeam system for three-dimensional multimodal materials analysis
journal, February 2012

The nucleation, growth and stability of micropits in stainless steel
journal, July 1994

Effect of grain refinement and electrochemical nitridation on corrosion resistance of the 316L stainless steel for bipolar plates in PEMFCs environment
journal, October 2015

Effect of surface roughness on early stages of pitting corrosion of Type 301 stainless steel
journal, September 1997

Computational simulation of metastable pitting of stainless steel
journal, November 2009

First-principles modeling of anisotropic anodic dissolution of metals and alloys in corrosive environments
journal, May 2017

Microstructure and corrosion behavior of 316L stainless steel prepared using different additive manufacturing methods: A comparative study bringing insights into the impact of microstructure on their passivity
journal, November 2020

Why stainless steel corrodes
journal, February 2002

Modulation of dendritic patterns during electrodeposition: A nonlinear phase-field model
journal, December 2015

Microstructure and Fracture Behavior of 316L Austenitic Stainless Steel Produced by Selective Laser Melting
journal, August 2016

Modeling the effect of insoluble corrosion products on pitting corrosion kinetics of metals
journal, July 2019

Controlling grain nucleation and morphology by laser beam shaping in metal additive manufacturing
journal, October 2020

An alternate explanation for the abrupt current increase at the pitting potential
journal, February 2008

Additively manufactured hierarchical stainless steels with high strength and ductility
journal, October 2017

Viewpoint: metallurgical aspects of powder bed metal additive manufacturing
journal, November 2015

Corrosion of Binder Jetting Additively Manufactured 316L Stainless Steel of Different Surface Finish
journal, January 2020

Correlation between process parameters, microstructure and properties of 316 L stainless steel processed by selective laser melting
journal, March 2018

Influence of scanning strategy and building direction on microstructure and corrosion behaviour of selective laser melted 316L stainless steel
journal, November 2021

Quantitative multiscale correlative microstructure analysis of additive manufacturing of stainless steel 316L processed by selective laser melting
journal, February 2020

The passivity of selective laser melted 316L stainless steel
journal, February 2020

Processing parameters in laser powder bed fusion metal additive manufacturing
journal, August 2020

Direct laser sintering of metal powders: Mechanism, kinetics and microstructural features
journal, July 2006

Surface treatment and corrosion behavior of 316L stainless steel fabricated by selective laser melting
journal, August 2019

Investigation of Influence of Surface Roughness on Pitting Corrosion of Duplex Stainless Steel 2205 using Various Electrochemical Techniques
journal, July 2019