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Corrosion deterioration of materials is a major problem affecting economic, safety, and logistical issues, especially in the aeronautical sector. Detecting the correct corrosion type in metal alloys is very important to know how to mitigate the corrosion problem. Electrochemical noise (EN) is a corrosion technique used to characterize the behavior of different alloys and determine the type of corrosion in a system. The objective of this research is to characterize by EN technique different aeronautical alloys (Al, Ti, steels, and superalloys) using different analysis methods such as time domain (visual analysis, statistical), frequency domain (power spectral density (PSD)), and frequency-time domain (wavelet decomposition, Hilbert Huang analysis, and recurrence plots (RP)) related to the corrosion process. Optical microscopy (OM) is used to observe the surface of the tested samples. The alloys were exposed to 3.5 wt.% NaCl and H2SO4 solutions at room temperature. The results indicate that HHT and recurrence plots are the best options for determining the corrosion type compared with the other methods due to their ability to analyze dynamic and chaotic systems, such as corrosion. Corrosion processes such as passivation and localized corrosion can be differentiated when analyzed using HHT and RP methods when a passive system presents values of determinism between 0.5 and 0.8. Also, to differentiate the passive system from the localized system, it is necessary to see the recurrence plot due to the similarity of the determinism value. Noise impedance (Zn) is one of the best options for determining the corrosion kinetics of one system, showing that Ti CP2 and Ti-6Al-4V presented 742,824 and 939,575 Ω·cm2, while Rn presented 271,851 and 325,751 Ω·cm2, being the highest when exposed to H2SO4.
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New manufacturing processes for metal parts such as additive manufacturing (AM) provide a technological development for the aeronautical and aerospace industries, since these AM processes are a means to reduce the weight of the parts, which generate cost savings. AM techniques such as Laser Powder Bed Fusions (LPBF) and Electron Beam Fusion (EBM), provided an improvement in mechanical properties, corrosion resistance, and thermal stability at temperatures below 400 °C, in comparison to conventional methods. This research aimed to study the oxidation kinetics of Ti-6Al-4V alloys by conventional and Electron Beam Additive Manufacturing. The thermogravimetric analysis was performed at temperatures of 600 °C, 800 °C, and 900 °C, having a heating rate of 25 °C/min and oxidation time of 24 h. The microstructural analysis was carried out by thermogravimetric analysis. Thickness and morphology of oxide layers were analyzed by field emission scanning electron microscope, phase identification (before and after the oxidation process) was realized by X-ray diffraction at room temperature and hardness measurements were made in cross section. Results indicated that the oxidation kinetics of Ti-6Al-4V alloys fabricated by EBM was similar to conventional processing and obeyed a parabolic or quasi-parabolic kinetics. The samples oxidized at 600 °C for 24 h presented the lowest hardness values (from 350 to 470 HV). At oxidation temperatures of 800 and 900 °C, however, highest hardness values (from 870 close to the alpha-case interface up to 300 HV in base metal) were found on the surface and gradually decreased towards the center of the base alloy. This may be explained by different microstructures presented in the manufacturing processes.
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The aim of this work was to evaluate the corrosion behavior of the AA6061 and AlSi10Mg alloys produced by extruded and additive manufacturing (selective laser melting, SLM). Alloys were immersed in two electrolytes in H2O and 3.5 wt. % NaCl solutions at room temperature and their corrosion behavior was studied by electrochemical noise technique (EN). Three different methods filtered EN signals, and the statistical analysis was employed to obtain Rn, the localization index (LI), Kurtosis, skew, and the potential spectral density analysis (PSD). The Energy Dispersion Plots (EDP) of wavelets method was employed to determine the type of corrosion and the Hilbert-Huang Transform (HHT), analyzing the Hilbert Spectra. The result indicated that the amplitude of the transients in the time series in potential and current is greater in the AlSi10Mg alloy manufactured by additive manufacturing. The amplitude of the transients decreases in both alloys (AA6061 and AlSi10Mg) as time increases.
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Selective laser melting (SLM) technology is ushering in a new era of advanced industrial production of metal components. It is of great importance to understand the relationship between the surface features and electrochemical properties of manufactured parts. This work studied the influence of surface orientation on the corrosion resistance of 316L stainless-steel (SS) components manufactured with SLM. The corrosion resistance of the samples was measured using linear polarization resistance (LPR) and electromechanical noise (EN) techniques under three different environments, H2O, 3.5 wt.% NaCl, and 20% H2SO4, analyzing the horizontal (XY) and vertical (XZ) planes. The microstructure and morphology of the samples were obtained by optical (OM) and scanning electron microscopy (SEM). The obtained microstructure showed the grains growing up from the fusion line to the melt pool center and, via SEM-EDS, the presence of irregular and spherical pores was observed. The highest corrosion rate was identified in the H2SO4 solution in the XZ plane with 2.4 × 10-2 mm/year and the XY plane with 1.31 × 10-3 mm/year. The EN technique along with the skewness factor were used to determine the type of corrosion that the material developed. Localized corrosion was observed in the NaCl electrolyte, for the XY and XZ planes (-1.65 and -0.012 skewness factors, respectively), attacking mainly the subgrains of the microstructure and, in some cases, the pores, caused by Cl ions. H2O and H2SO4 solutions presented a uniform corrosion mechanism for the two observed orientations. The morphology identified by SEM was correlated with the results obtained from the electrochemical techniques.
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The titanium alloy, Ti6Al4V, is used in dentistry for dental implants because of its excellent resistance to corrosion and its high biocompatibility. However, periimplantitis is considered the main reason for treatment failure. The Ti6Al4V alloy was used to study the corrosion behavior for dental implant applications, using an experimental arrangement of three electrodes with the bacteria Streptococcus gordonii and Fusobacterium nucleatum, in addition to Ringer's lactate as electrolytes, at 37 °C and a pH of 5.6. Their electrochemical behavior was studied by open circuit potential (OCP) and cyclic potentiodynamic polarization (CPP) according to ASTM G3-14 and ASTM G61-11, respectively. Scanning electron microscopy (SEM) was employed to determine the morphology of the alloy studied. An experimental model, in situ, was established with the bacteria present in an oral environment to understand the electrochemical behavior of the alloy used in dental implants. The greatest corrosion in Ti6Al4V alloy was produced by the medium that contained the bacterium Streptococcus gordonii, which is considered a primary colonizer. In addition, the Ti6Al4V alloy presented uniform corrosion in the three solutions at the different exposure times showing a negative hysteresis in CPP.
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Increasingly stringent environmental regulations in different sectors of industry, especially the aeronautical sector, suggest the need for more investigations regarding the effect of environmentally friendly corrosion protective processes. Passivation is a finishing process that makes stainless steels more rust resistant, removing free iron from the steel surface resulting from machining operations. This results in the formation of a protective oxide layer that is less likely to react with the environment and cause corrosion. The most commonly used passivating agent is nitric acid. However, it is know that high levels of toxicity can be generated by using this agent. In this work, a study has been carried out into the electrochemical behavior of 15-5PH (precipitation hardening) and 17-4PH stainless steels passivated with (a) citric and (b) nitric acid solutions for 60 and 90 min at 49 °C, and subsequently exposed to an environment with chlorides. Two electrochemical techniques were used: electrochemical noise (EN) and potentiodynamic polarization curves (PPC) according to ASTM G199-09 and ASTM G5-13, respectively. The results obtained indicated that, for both types of steel, the passive layer formed in citric acid as passivating solution had very similar characteristics to that formed with nitric acid. Furthermore, after exposure to the chloride-containing solution and according with the localization index (LI) values obtained, the stainless steels passivated in citric acid showed a mixed type of corrosion, whereas the steels passivated in nitric acid showed localized corrosion. Overall, the results of the R n values derived show very low and similar corrosion rates for the stainless steels passivated with both citric and nitric acid solutions.