Chloride Induced Secondary Passive Film Failure for Laser Additive Manufacturing Nickel-Based Superalloys during Electrochemical Machining

Guo, Pengfei; Lin, Xin; Macdonald, Digby D.; Odnevall, Inger; Zhang, Shaoli; Zhang, Yufeng; Lin, Changjian; Wu, Qiang; Yang, Yuan; Huang, Weidong

doi:10.1149/1945-7111/acdafd

Cited by 5 publications

(2 citation statements)

References 29 publications

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“…7,26,27 The surface finish in ECM is closely related to the anodic interface structure, which has been demonstrated to be a metal/ supersaturated salt film structure in the NaCl electrolyte and a metal/ transpassive film/supersaturated salt film structure in NaNO 3 electrolytes for both Fe and SS304 steel under ECM conditions. 5,6,38,39 To characterize some aspects of the interface in detail, electrochemical methods including coulometry and the galvanostatic pulse technique were applied using the developed cell. After dissolution of Fe at 25 A cm −2 for 4 s, coulometry was conducted in situ by cathodic potential scanning from 0 to −2 V at a rate of 0.01 V s −1 .…”

Section: Test System and Experimentsmentioning

confidence: 99%

Developing a New Flow Cell for Electrochemical Machining Anodic Dissolution Investigations by Simulation-Based Design and 3D Printing

Liu,

Li,

Zhao

et al. 2023

J. Electrochem. Soc.

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Electrochemical machining (ECM) is an essential non-traditional industrial shaping technology. An in-depth understanding of ECM anodic dissolution is fundamentally important for process parameter design and optimization. However, the existing electrochemical setups face challenges in achieving efficient analysis of these processes. In this work, a new flow cell has been developed via simulation-based design and 3D printing that demonstrates comprehensive advantages in terms of improved electric and flow conditions, measurement technique versatility, and production simplicity at low cost. Simulations are performed to reveal particular characteristics of the proposed cell in terms of physical distributions and to determine its key dimensions with high efficiency. The stereo lithography technique is used to realize the complex design and fabricate the proposed flow cell, thus ensuring ease of accessibility. Furthermore, the effectiveness of the developed cell is verified experimentally by examining the anodic behavior of typical metals in common ECM electrolytes, using Fe and SS304 stainless steel as examples. Test results show that information on the polarization behavior, current efficiency, anodic interface structure, and surface finish can be obtained conveniently and the results agree with previous findings, demonstrating the potential of the developed cell to perform high throughput tests to study ECM fundamentals.

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Section: Test System and Experimentsmentioning

confidence: 99%

Developing a New Flow Cell for Electrochemical Machining Anodic Dissolution Investigations by Simulation-Based Design and 3D Printing

Liu,

Li,

Zhao

et al. 2023

J. Electrochem. Soc.

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“…Electrochemical corrosion technology is crucial for exploring metals and alloys' corrosion resistance in seawater and studying biological implants [15][16][17]. Guo et al investigated the effect of chlorides on the secondary passivation film (SPF) of the laser additive manufacturing nickel-based superalloys by electrochemical machining [18]. Kretzmer et al studied the effect of chromium and molybdenum on the growth of electrochemical oxides in nickel and commercial nickel alloys [19].…”

Section: Introductionmentioning

confidence: 99%

Mechanical characteristics and electrochemical corrosion of NiCoCr alloys

Lu,

Bui,

Fang

2024

Phys. Scr.

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Previous studies have shown that NiCoCr medium entropy alloys (MEAs) have perfect strength-ductility balance and significant escape fracture toughness. This work aimed to determine the effects of annealing temperature and alloy composition on the mechanical characteristics and corrosion behaviors of the NiCoCr MEAs. The results showed that the grains generated in the NiCoCr MEAs became more petite with the cooling rate increasing. The Vickers hardness (HV) of annealed NiCoCr MEAs increased with increasing annealing temperature. For NiCoCr alloys with different alloy compositions, the potentiodynamic polarization results showed that the NiCoCrFeMn alloy has the highest polarisation resistance, lowest current density, and lowest corrosion rate. However, the composition of Fe2O3-based passivation film makes it highly reactive and easily cleaved by Cl-. The NiCoCr and NiCoCrFe MEAs with high Ni content had a denser and slowly dissolved NiO passivation layer and better corrosion resistance. Moreover, the hardness of corroded NiCoCr MEAs decreased by 7.7 %.

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Perspective: revisiting surface roughness in electrochemical machining and the paradoxes

Pan,

Zhao,

Balaji

et al. 2024

Surf. Sci. Tech.

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Electrochemical machining (ECM) represents a prominent electrochemistry-driven technique for surface flattening, post-processing, and (ultra-)precision machining, attracting considerable research interests recently. The method exhibits advantages in the machining of hard-to-machine nickel (Ni) superalloys, particularly those created via additive manufacturing approaches such as laser powder bed fusion (LPBF), in which enhanced microstructural features and mechanical properties are achieved with compromised surface quality. This study explores the intricate relationship between Ni alloy-specific microstructures, such as carbide precipitates, and the principles of electrochemistry integral to ECM. It further emphasizes the emerging requirement to re-examine the surface quality outcomes of ECM. We present a concise overview of the inherent paradoxes in ECM, encompassing the prediction of surface roughness range, the quantification of charge transfer coefficients, the efficiency of material removal, and the temporal dependence of the ECM process. These paradoxes necessitate systematic experimental and theoretical research to advance our understanding, and we wish to welcome, stimulate, and urge more raised awareness and attention to this matter about ECM surface quality control and prediction.

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Chloride Induced Secondary Passive Film Failure for Laser Additive Manufacturing Nickel-Based Superalloys during Electrochemical Machining

Cited by 5 publications

References 29 publications

Developing a New Flow Cell for Electrochemical Machining Anodic Dissolution Investigations by Simulation-Based Design and 3D Printing

Developing a New Flow Cell for Electrochemical Machining Anodic Dissolution Investigations by Simulation-Based Design and 3D Printing

Mechanical characteristics and electrochemical corrosion of NiCoCr alloys

Perspective: revisiting surface roughness in electrochemical machining and the paradoxes

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