About this Abstract |
Meeting |
2025 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2025)
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Symposium
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2025 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2025)
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Presentation Title |
Stress-Corrosion Behavior of Magnesium Alloy AZ91 Manufactured by Laser Powder Bed Fusion |
Author(s) |
Chelsea O'Donnell, Alejandro Avila, Bradley Kauffman, Adrian Passinger, Robert Stewart, David Scott Fernander, Dina Khattab, Michael Titus, Michael P. Sealy |
On-Site Speaker (Planned) |
David Scott Fernander |
Abstract Scope |
This study investigated how laser powder bed fusion (LPBF) processing parameters affect the stress-corrosion behavior of AZ91 magnesium alloy, a lightweight material of interest for aerospace and marine components. The hypothesis was that porosity-driven stress localization accelerates corrosion under tensile stress. LPBF parameters (i.e., laser power and scan speed) were varied to modulate energy density and generate distinct porosity features. Open circuit potential and potentiodynamic polarization tests were conducted under applied tensile load (60 MPa) to characterize corrosion response. Results showed that corrosion rates decreased with build height, suggesting improved microstructure or stress relief near the substrate. Surprisingly, some suboptimal samples exhibited lower corrosion rates under load, contrary to expectations. These trends suggest that both porosity morphology and build height contribute to stress-corrosion behavior in magnesium. This work contributes to AM design frameworks that account for corrosion performance under service-relevant loading. |
Proceedings Inclusion? |
Planned: Post-meeting proceedings |