Corrosion of Additively Manufactured Metallic Components: A Review

The unique additive manufacturing (AM) attributes such as tool-less design, on-site fabrication, short production cycle, and complex structures fabrication can make AM market penetration deeper. The sustained improvements in AM’s computational hardware and software, advanced automation, affordable equipment, and process, structural, and metallurgical understanding are likely to contribute to AMs’ more comprehensive commercial adaptation. However, several scientific and technological issues like process-induced defects and microstructural heterogeneity limit its growth in replacing conventional products. AM mechanical properties are comparable to those produced conventionally, and the same is true about its corrosion behavior. However, AM process uncertainties can vary part properties, causing significant discrepancies in corrosion results. Controlling corrosion in AM alloys requires a proper understanding of the process and microstructural evolution. Optimizing processing conditions is critical for part’s high productivity and minimal defects. Similarly, post-processing conditions are vital to infuse desired mechanical and chemical properties. Regardless of the processing conditions, corrosion is integral to material stability that needs scientific input to understand and develop mechanical and microstructural properties for excellent corrosion-resistant AM materials. This study aims to analyze the scientific work done in the corrosion analysis of AM materials and to suggest future work potentials.