Corrosion performance of wire arc additively manufactured NAB alloy

Abstract

Nickel–aluminum bronzes (NAB) are vital alloys, known for biofouling resistance, crucial for marine and shipbuilding industries. This study examined corrosion performance of NAB samples fabricated by wire arc additive manufacturing (WAAM) in as-built and heat-treated conditions. Microstructural analysis revealed the WAAM-NAB parts primarily consisted of the α-phase (copper) and three types of κ-phases: κII (spherical Fe3Al), κIII (Ni–Al in lamellar shape) within the interdendritic areas, and iron-rich κIV particles dispersed throughout the matrix. In contrast, casting-produced NAB showed the formation of a rosette-like κI phase as well. Corrosion behavior comparisons between the two NAB fabrication methods were also assessed. The microstructural characterizations revealed a rise in the size of the κIV particles after heat-treated at 350 °C for 2 h (HT1). Heat treatment at 550 °C for 4 h (HT2) resulted in a needle-like κV, coarsening of κII, partial spheroidization of κIII, and reduced κIV precipitation. When heat-treated to 675 °C for 6 h (HT3), κII and κV were coarsened, κIII was completely spheroidized, and κIV precipitation was significantly reduced. These microstructural features in HT2 and HT3 conditions steeply decreased their corrosion resistance compared to the WAAM as-built part. The as-built WAAM sample showed superior corrosion resistance in chloride solution, attributed to fewer κ-intermetallic phases and a finer microstructure. The κ-phases, irrespective of morphology, act as the cathodic areas versus the α-dendritic matrix, fostering microgalvanic cell formation. Consequently, precipitation of all cathodic κ-phases draws a higher galvanic current of the anodic α-phase, meaning a lower corrosion resistance.