Corrosion Evaluation of Metal Binder-Jetted Stainless Steel Parts: Influence of Printing Parameters on Performance

Abstract

Additive manufacturing is a rapidly expanding fabrication process in both research and industry, capable of constructing parts layer by layer from a 3D CAD model. ASTM recognizes seven distinct additive manufacturing processes, with the majority capable of producing metal components. Among these technologies, binder jetting stands out, offering the potential to create a variety of metallic parts for applications in the biomedical and energy sectors at reduced costs and shorter lead times. Achieving acceptable corrosion resistance is crucial for such applications. Binder jetting exhibits advantages such as relatively high part density (~99%) and good surface roughness (~6μm for as-sintered parts), making it an ideal candidate for investigating corrosion behavior, given the general correlation between low surface roughness, high density, and improved corrosion performance. Despite its promise, binder jetting lacks standardized procedures for producing parts with specific properties, necessitating users to determine parameters through trial and error. The corrosion behavior of parts created through binder jetting remains uncertain due to various influencing parameters. This study focuses on two key printing factors: layer thickness and binder saturation, chosen due to their impact on surface roughness, density, and thereby on corrosion. Existing literature suggests that increased layer thickness may reduce powder bed density, potentially affecting green part density and causing more significant shrinkage during sintering. Simultaneously, binder saturation is recognized as a critical factor influencing final part quality. Predicting the combined impact of layer thickness and binder saturation on corrosion performance proves challenging. To unravel this relationship, we conducted experiments using an ExOne Innovate Plus metal binder jetting machine and 316L stainless steel metal powder (mean powder size of 22μm) which is widely recognized as the most common powder in research. A number of test runs were conducted by varying layer thickness and binder saturation, offering insights into their nuanced interplay in the context of corrosion performance. Initially, to address insufficient green strength, printer drying time and curing cycle time were optimized by conducting a series of experiments changing the drying time and curing time. Subsequent printing involved changing binder saturation parallel to the layer thickness variations, resulting in distinct parts with varying properties. Then the predetermined curing cycle was executed, followed by de-powdering, and sintering in a furnace. Sintering is imperative to increase the part density and enhance the overall strength of the final product. However, it's essential to acknowledge that sintering may adversely impact corrosion resistance due to the remaining porosity and surface fissures. The choice of sintering profile becomes crucial, necessitating careful consideration to minimize elemental migration during sintering and mitigate porosity. Scanning electron microscopy and optical microscopy are used to analyze sintered parts and interpret corrosion mechanisms. Electrochemical tests were conducted to identify corrosion rates, corrosion potential, passivation behavior, pitting potential, etc. in contrast with conventionally manufactured 316L in M NaCl solution. This study offers insights and recommendations aimed at enhancing the corrosion resistance of binder jetted stainless steel parts.