On the corrosion of additively manufactured aluminium alloy AA2024 prepared by selective laser melting

O. Gharbi, D. Jiang, D. R. Feenstra, S. K. Kairy, Y. Wu, C. R. Hutchinson, N. Birbilis

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The microstructure, and electrochemical properties of additively manufactured Al-alloy AA2024 (AM2024, Al-Cu-Mg) produced by selective laser melting are reported. In-depth microstructural characterisation was conducted to compare the resultant microstructure, including phase identification, size and distribution, against the wrought counterpart AA2024-T3. The prospect of producing net shape Al-alloys via additive manufacturing (AM) has the potential to provide cost effective and high specific strength components. It was revealed that the dominant second phase formed in AM2024 was Al 2 Cu (θ–phase), in contrast to the typical Al 2 CuMg (S-phase) observed in AA2024-T3. The AM2024 also revealed a refined microstructure, with an average constituent particle size < 1 μm. Thermodynamic calculations revealed that the preferential formation of θ-phase was influenced by the Si content of AM2024 (0.78 wt. %). Atomic emission spectroelectrochemistry (AESEC) measurements revealed a lower Al dissolution rate (5 times) in the case of AM2024. Anodic polarisation revealed that AM2024 was capable of forming an appreciable surface oxide relative to AA2024-T3. The findings herein demonstrate the possibilities of AM as applied to a high strength Al-alloy.

Original languageEnglish
Pages (from-to)93-106
Number of pages14
JournalCorrosion Science
Publication statusPublished - 1 Oct 2018


  • AA2024
  • Additive manufacturing
  • Aluminium alloys
  • Corrosion
  • Selective laser melting

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