Correlation of LPBF process parameters and heat treatment with the corrosion behavior of AlSi10Mg alloy

This study investigates the corrosion resistance of LPBF-fabricated AlSi10Mg alloy, focusing on the interplay between process parameters and heat treatments. Volumetric energy densities ranging from 32 to 117 J/mm(3) were employed, resulting in different microstructural features and defect types, including lack-of-fusion and keyhole pores. Electrochemical Impedance Spectroscopy (EIS) and Potentiodynamic Polarization (PDP) tests conducted in a 3.5 wt.% NaCl solution demonstrated that lower energy densities (< 78 J/mm(3)) exhibited improved corrosion resistance, while higher energy densities (>= 78 J/mm(3)) led to accelerated corrosion. Stress-relief heat treatments were conducted on the samples with the best and worst corrosion resistance based on process parameters. Treatment at 200 degrees C had negligible impact on the silicon network and caused only a slight reduction in corrosion resistance, while treatment at 300 degrees C disrupted the silicon network near melt pool boundaries, leading to intensified selective corrosion.