Research progress on the influence of microstructure characteristics of metal additive manufacturing on its corrosion resistance
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摘要: 金屬增材制造是增材制造技術中最重要的分支，其成形零件復雜度高，力學性能高于一般鑄件，已經被廣泛應用于航天航空、醫療、能源等領域。在目前主流金屬增材制造過程中，主要使用高能束熔化金屬粉體，從而造成極高的材料過冷度，雖然過冷細化晶粒與特殊析出相會提高材料的力學性能，但是學術界與工業界對金屬增材制造制件在服役過程中的腐蝕性能仍然存在疑問，亟需關于高能束金屬增材制造制件的抗腐蝕性能系統性研究綜述。因此，本文就三種常用的金屬增材制造技術，對目前金屬增材制造工件的腐蝕性能相關研究進展進行總結和歸納，深入研究了打印產品中的殘余應力、晶粒尺寸、析出相和各向異性等影響抗腐蝕性能的行為，分析了參數優化及熱處理工藝提高材料抗腐蝕性能的機理。最后對金屬增材制造的抗腐蝕性能的改善手段進行了展望。Abstract: Additive manufacturing technology is a method of manufacturing parts that are stacked layer by layer through the principle of discrete stacking, which is different from traditional subtractive manufacturing. It has been widely concerned due to its advantages of short process flow, high material-utilization rate, and highly flexible manufacturing. Additive metal manufacturing is the most important branch of additive manufacturing technology. Its forming parts have high complexity, showing excellent mechanical properties than ordinary castings. After more than 20 years of development, it has been widely used in aerospace, medical, energy, and other related fields. In the current mainstream metal material in the manufacturing process, the main use of high-energy beam-melting metal powders results in extremely high overcooling, whereas cold fine grains exhibit special precipitation and increase the mechanical properties of the material. However, there are still doubts about the corrosion performance of metal additive manufacturing parts in the service process. The mechanism of the corrosion effect of special microstructures and precipitation relative to materials in the service process is still unclear. Therefore, it is urgent to review the systematic research of the corrosion resistance of high-energy beam metal additive manufacturing parts. Corrosion resistance is also one of the key factors for metal additive manufacturing products to occupy a place in the market and should be paid attention to. Therefore, this article summarized the current research progress on the corrosion performance of metal additive manufacturing workpieces on three commonly used metal additive manufacturing technologies: laser melting, electron beam melting, and directional metal deposition. The residual stress, grain size, precipitated phase, and anisotropy affect the corrosion resistance behavior. The influence mechanism of the parameter optimization and heat-treatment process on the corrosion resistance of the material was analyzed. Finally, the prospects of improving the corrosion resistance of metal additive manufacturing products were discussed.
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圖 4 SLM制造的AlSi10Mg樣品掃描電鏡圖像(SEM)[21]。（a~c）為俯視圖；（d~f）為側視圖；（b, c）顯示了熔池中心的精細蜂窩狀微結構；（c, f）顯示了高放大率下熔池邊界和周圍區域的粗糙微結構
Figure 4. SEM image of the AlSi10Mg sample manufactured by SLM[21]: (a–c) top view; (d–f) side view; (b, c) fine cellular microstructure of the core (center) of the melt pool; (c, f) coarse microstructure of the melt pool boundary and surrounding regions at high magnification
圖 11 DED打印316L不銹鋼顯微組織的TEM圖[49]。（a）高倍放大奧氏體；（b）奧氏體晶胞的電子衍射圖；（c）鐵素體晶胞的電子衍射圖
Figure 11. TEM images of the microstructure of the DED-produced 316L stainless steel[49]: (a) high magnification of austenite; (b) electron diffraction pattern taken from an austenite cell; (c) an electron diffraction pattern taken from an intercellular ferrite
圖 17 在陽極極化測試期間Al、Fe、Cu和Mg元素的溶解曲線（虛線itot代表從恒電位儀收集的總電流信號；灰色陰影區域說明了itot和iAl之間的差異；陰影面積增大代表了利于氧化鋁膜的形成和生長）[62]。（a）AA2024-T3；（b）AM2024
Figure 17. During the anodization test, the dissolution curves of Al, Fe, Cu and Mg elements, (the dotted line itot represents the total current signal collected from the potentiostat; the gray shaded area illustrates the difference between itot and iAl; the increased shadow area represents the formation and growth of alumina film)[62]: (a) AA2024-T3; (b) AM2024
表 1 0.6 mol·L?1 NaCl溶液中SLM-316L與鍛造316L電化學數據（ΔE是指樣品的鈍化層穩定電位范圍）[37]
Table 1. Electrochemical data of SLM-316L and forged 316L in 0.6 mol·L?1 NaCl solution (ΔE refers to the stable potential range of the passivation layer of the sample) [37]
Sample Ecorr/VSCE icorr/(μA·cm–2) ΔE/VSCE Wrought ?0.471 4.16 0.463 Wrought (heat treated) ?0.434 2.69 0.564 Printed ?0.362 1.29 0.609 Printed (heat treated) ?0.347 1.14 0.613 
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表 2 0.1 mol·L?1 NaCl溶液中SLM-316L與常規制造316L電化學數據[40]
Table 2. Electrochemical data of SLM-316L and as-cast 316L in a 0.1 mol·L?1 NaCl solution[40]
Sample icorr/(nA?mm–2) Ecorr/VSCE Epit/VSCE SLM-SD 11.2±4 ?0.10±0.07 1.08±0.09 SLM-BD 17.2±1 ?0.10±0.06 0.54±0.03 CM 50.3±3 ?0.18±0.05 0.48±0.02 Note: SD—horizontal direction; BD—vertical direction; CM—
conventionally manufactured.
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表 3 0.1 mol·L?1 NaCl溶液中SLM-Al–12Si與鑄態Al–12Si電化學數據[40]
Table 3. Electrochemical data of SLM-Al–12Si and as-cast Al–12Si in a 0.1 mol·L?1 NaCl solution[40]
Sample icorr/(nA?mm–2) Ecorr/VSCE Epit/VSCE SLM-SD 398.4±53 ?0.68±0.03 — SLM-BD 453.2±35 ?0.69±0.02 — Casting 1047.2±100 ?0.72±0.02 —
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表 4 SLM和商用Al–Mg–Cu–Si合金的腐蝕電位和點蝕電位[59]
Table 4. Corrosion potential and pitting potential of SLM and commercial Al–Mg–Cu–Si alloys[59]
Sample Ecorr/VSCE Epit/VSCE 0.001 M NaCl, SLM alloy –0.570 –0.420 0.001 M NaCl, AA2024 –0.591 –0.522 0.1 M NaC, SLM alloy –0.686 –0.512 0.1 M NaCl, AA2024 –0.694 –0.691
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表 5 SLM打印TC4合金XY面XZ面相結構具體組成[67] （V為體積分數）
Table 5. Phase composition of XY and XZ planes of the SLM-produced TC4 alloy[67] (V is volume fraction)
Sample Phase composition Vα or Vα'/% Vβ/% SLM-produced, XY-plane α'＋β 88.1 11.9 SLM-produced, XZ-plane α'＋β 95.0 5.0
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