Critical role of slags in pitting corrosion of additively manufactured stainless steel in simulated seawater

Shohini Sen-Britain, Seongkoo Cho, ShinYoung Kang, Zhen Qi, Saad Khairallah, Debra Rosas, Vanna Som, Tian T. Li, S. Roger Qiu, Y. Morris Wang, Brandon C. Wood and Thomas Voisin ()
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Shohini Sen-Britain: Lawrence Livermore National Laboratory
Seongkoo Cho: Lawrence Livermore National Laboratory
ShinYoung Kang: Lawrence Livermore National Laboratory
Zhen Qi: Lawrence Livermore National Laboratory
Saad Khairallah: Lawrence Livermore National Laboratory
Debra Rosas: Lawrence Livermore National Laboratory
Vanna Som: Lawrence Livermore National Laboratory
Tian T. Li: Lawrence Livermore National Laboratory
S. Roger Qiu: Lawrence Livermore National Laboratory
Y. Morris Wang: University of California Los Angeles
Brandon C. Wood: Lawrence Livermore National Laboratory
Thomas Voisin: Lawrence Livermore National Laboratory

Nature Communications, 2024, vol. 15, issue 1, 1-13

Abstract: Abstract Pitting corrosion in seawater is one of the most difficult forms of corrosion to identify and control. A workhorse material for marine applications, 316L stainless steel (316L SS) is known to balance resistance to pitting with good mechanical properties. The advent of additive manufacturing (AM), particularly laser powder bed fusion (LPBF), has prompted numerous microstructural and mechanical investigations of LPBF 316L SS; however, the origins of pitting corrosion on as-built surfaces is unknown, despite their utmost importance for certification of LPBF 316L SS prior to fielding. Here, we show that Mn-rich silicate slags are responsible for pitting of the as-built LPBF material in sodium chloride due to their introduction of deleterious defects such as cracks or surface oxide heterogeneities. In addition, we explain how slags are formed in the liquid metal and deposited at the as-built surfaces using high-fidelity melt pool simulations. Our work uncovers how LPBF changes surface oxides due to rapid solidification and high-temperature oxidation, leading to fundamentally different pitting corrosion mechanisms.

Date: 2024
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DOI: 10.1038/s41467-024-45120-6

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