Effect of Laser Metal Deposition Parameters on the Characteristics of Stellite 6 Deposited Layers on Precipitation-Hardened Stainless Steel

Laser metal deposition (LMD) is one of the manufacturing processes in the industries, which is used to enhance the properties of components besides producing and repairing important engineering components. In this study, Stellite 6 was deposited on precipitation-hardened martensitic stainless steel (17-4 PH) by using the LMD process, which employed a pulsed Nd:YAG laser. To realize a favor deposited sample, the effects of three LMD parameters (focal length, scanning speed, and frequency) were investigated, as well as microstructure studies and the results of a microhardness test. Some cracks were observed in the deposited layers with a low scanning speed, which were eliminated by an augment of the scanning speed. Furthermore, some defects were found in the deposited layers with a high scanning speed and a low frequency, which can be related to the insufficient laser energy density and a low overlapping factor. Moreover, various morphologies were observed within the microstructure of the samples, which can be attributed to the differences in the stability criterion and cooling rate across the layer. In the long run, a defect-free sample (S-120-5.5-25) possessing suitable geometrical attributes (wetting angle of 57° and dilution of 25.1%) and a better microhardness property at the surface (≈335 Hv) has been introduced as a desirable LMDed sample.

Effect of Redox Mediators on Corrosion Behavior and Scanning Electrochemical Microscopy Response

Scanning electrochemical microscopy (SECM) is widely used to measure local electrochemical reactivity of corroding surfaces. A major criticism of using SECM in feedback mode for corrosion studies is the requirement of an external redox mediator (RM) as it could react with the metal and affect the Nernst potential at the metal-solution interface. Consequently, it becomes challenging to differentiate the interference caused by the RM from the local reactivity of the metal. Herein, a multiscale electrochemical approach is presented to investigate the effect of RM choice on the corroding substrate. Two common RMs, ferrocenemethanol and hexaammineruthenium(III) chloride, were used to perform SECM over copper and aluminum. It was found during macroscale electrochemical measurements that Ru(NH)63+ acted as an oxidant and promoted corrosion. The SECM feedback behavior varied for copper depending on the RM used, suggesting that the corrosion reactions controlled the negative feedback mechanism, not the formation of an insulating passive film. The passivated aluminum surface consistently exhibited negative feedback, regardless of the RM used. SECM approach curves also displayed a distortion in the steady state current, which was caused by the deposition of substrate-generated species on the microelectrode. These deviations in feedback response were accounted for during analysis through incorporation into a finite element model to accurately extract the RM kinetic rate constants. The importance of understanding these processes is highlighted to avoid misinterpretation of passive behavior and advances toward a more quantitative use of SECM for corrosion studies.