Corrosion performance of corrosion resistant alloys produced by wire arc additive manufacturing

In this section

Back to Core Research Programme AMorph – 4D Printing for Field Morphing Structures Automation of Composite and Hybrid Joining Process Coaxial Wire Additive Manufacturing Processes and In-Line Monitoring Tools Development of Coded Excitation Technique for Non-Metallic Pipes Inspection Development of Digital Twin technology as a demonstrator for real-time integrity assessment of crack growth in tensile specimens Development of Friction Stir Welding (FSW) for Hydrogen Fuel Storage Tanks Development of Leak-Before-Break Hydrogen Storage Composite Pressure Vessels With Polymeric Liner Establishing Assessment Methods for Determining Safe Service Limits of High-Temperature Materials in Extreme Environments Fracture toughness in aggressive environments: effect of crack monitoring techniques on test results In-process detection and non-destructive testing of electron beam weld imperfections Internal Bore Coatings for Applications in Corrosion and Hydrogen Environment Joining of Additively Manufactured Materials Long term behaviour of polymeric liner materials/coatings in hydrogen service Techniques for High Temperature Ultrasonic Inspection of Arc Welding Ultimate Leverage Fund

Project Code: 35845

Start date and planned duration: February 2024, 36 months

Objective

Develop procedures for manufacturing defect-free wire arc additively manufactured (WAAM) material for three corrosion resistant alloys (CRAs) to demonstrate TWI’s ability to achieve WAAM manufacturing capability in challenging materials
Provide TWI Industrial Members with a comprehensive dataset showing the microstructure-process parameter relationship and its effect on corrosion performance of WAAM CRAs
Develop novel post-processing procedures to improve the corrosion performance of WAAM CRAs.

Project Outline

The project will expand current knowledge of corrosion properties of CRAs manufactured by WAAM. Specifically, the following topics will be analysed in-depth by performing standardised and bespoke testing:

The effect of manufacturing process parameters on corrosion properties. This will help understand the performance of as-deposited material and possible mitigation strategies at the deposition stage by adjusting process parameters
Investigate common post-processing methods, such as heat treatment, and their effect on the corrosion performance of the material
Routine laboratory-based corrosion testing methods will be used to understand the susceptibility of WAAM CRAs to corrosion (for example, ASTM G48, ASTM G150, ASTM A262)
Electrochemical corrosion testing will be performed, such as potentiodynamic polarisation scans, in solutions appropriate for each CRA and its intended operating environment.

Industry Sectors

- Oil and Gas

- Aerospace

- Power

Benefits to Industry

CRAs are often deployed in challenging environments requiring a combination of excellent mechanical properties and corrosion resistance. Given the considerable expense associated with CRAs, there is a desire to take advantage of near net shape manufacturing processes, such as additive manufacturing. Industry is keen to employ high deposition rate techniques such as WAAM to manufacture components for harsh environments using such alloys; however, there remains a lack of information on the likely corrosion resistance of many CRAs.

This project will seek to address many of the challenges associated with the manufacture of CRAs through WAAM and the associated impact this has on corrosion resistance. The outcomes of this work will be beneficial to TWI members seeking to produce CRA components via WAAM for use in corrosive environments.