3D printing (or more formally called additive manufacturing) has the potential to revolutionize the way objects are manufactured, ranging from critical applications such as aerospace components to medical devices, making the materials stronger, lighter and more durable than those manufactured via conventional methods. While the mechanical properties of Ti-6Al-4V parts manufactured with two major 3D printing techniques: selective laser melting (SLM) and electron beam melting (EBM), have been reported, it is unknown if the corrosion resistance of the 3D-printed parts is comparable to that of the alloy made with isothermal forging (ISF). The aim of this study was to identify the corrosion resistance and mechanisms of Ti-6Al-4V alloy manufactured by SLM, EBM and ISF via electrochemical corrosion tests in 3.5% NaCl solution, focusing on the effect of microstructures. It was observed that the equiaxed α + β microstructure in the ISF-manufactured Ti-6Al-4V alloy had a superior corrosion resistance to the acicular martensitic α' + β and lamellar α + β microstructures of the 3D-printed samples via SLM and EBM, respectively. This was mainly due to the fact that (1) a higher amount of β phase was present in the ISF-manufactured sample, and (2) the fraction of phase interfaces was lower in the equiaxed α + β microstructure than in the acicular α' + β and lamellar α + β microstructures, leading to fewer microgalvanic cells. The lower corrosion resistance of SLM-manufactured sample was also related to the higher strain energy and lower electrochemical potential induced by the presence of martensitic twins, resulting in faster anodic dissolution and higher corrosion rate.
Keywords: Ti-6Al-4V alloy; additive manufacturing; corrosion resistance; electron beam melting; isothermal forging; selective laser melting; three-dimensional (3D) printing.