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激光粉末床熔融成形Al-Si-Fe-Mn-Ni-Sc-Zr合金的组织形貌及腐蚀行为研究

Microstructure and Corrosion Behavior of Al-Si-Fe-Mn-Ni-Sc-Zr Alloy Processed by Laser Powder Bed Fusion

  • 摘要: 本研究旨在探讨不同比例Al-Mg-Sc-Zr合金添加对激光粉末床熔融(PBF-LB)成形Al-Si系合金组织及腐蚀行为的影响。通过向Al-Si-Fe-Mn-Ni合金粉末中分别添加10 wt.%、20 wt.%、30 wt.%的Al-Mg-Sc-Zr粉末,制备得到Al-Si-Fe-Mn-Ni-Sc-Zr交叉合金(Cross-over alloy)粉末,并对比分析了经PBF-LB成形后微观组织、电化学性能和浸泡腐蚀形貌的差异。结果表明,适量的Al-Mg-Sc-Zr粉末添加可有效抑制PBF-LB成形交叉合金等轴晶区和柱状晶区晶粒的长大,细化等轴晶区α-Al晶粒尺寸和Si网络结构,并减小柱状晶区Si颗粒的尺寸(10-100 nm)。电化学测试结果显示,ASF-M10合金相比于ASF-M0合金,表现出更高的阻抗、更低的腐蚀电流密度和优异的抗点蚀性能;而ASF-M20和ASF-M30合金的抗腐蚀性能则较ASF-M0合金有所下降。浸泡腐蚀形貌分析表明,随着Al-Mg-Sc-Zr合金的添加,ASF-M合金连续层间腐蚀被抑制,出现少量点蚀坑;主要是因为细化的Si网状组织可有效抑制电偶腐蚀,同时,Mg元素能够起到稳定氧化膜的作用。

     

    Abstract: This study was conducted to clarify the influence of different addition levels of an Al-Mg-Sc-Zr alloy on the microstructure and corrosion behavior of Al-Si-based alloys fabricated via powder bed fusion-laser beam (PBF-LB). Al-Si-Fe-Mn-Ni-Sc-Zr cross-over alloy powders were prepared by incorporating 10 wt.%, 20 wt.% and 30 wt.% of Al-Mg-Sc-Zr powder into the Al-Si-Fe-Mn-Ni master powder. After PBF-LB processing, the microstructures, electrochemical properties and immersion corrosion morphologies of the as-built alloys were systematically characterized and compared. The results demonstrated that a moderate addition of Al-Mg-Sc-Zr effectively suppressed grain coarsening in both the equiaxed-grain and columnar-grain regions. Specifically, the α-Al grains in the equiaxed zone were refined, accompanied by the formation of a finer Si network, while the Si particles in the columnar zone were refined to a size range of 10-100 nm. Electrochemical measurements revealed that the cross-over alloy with ASF-M10 addition exhibited higher impedance and a lower corrosion current density and excellent pitting corrosion resistance than the master alloy. In contrast, the cross-over alloys with ASF-M20 and ASF-M30 additions showed reduced corrosion resistance compared with the master alloy. Further Analysis of immersion corrosion morphology indicated that with the addition of Al-Mg-Sc-Zr alloy, the intergranular corrosion of ASF-M alloy is suppressed, and only a few pitting corrosion pits appear. This transition was mainly attributed to two factors: first, the refined Si network structure weakened the micro-galvanic coupling effect; second, the presence of Mg promoted the formation of a more stable surface oxide film.

     

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