Corrosion of an Additively Manufactured Ti6Al4V Alloy in Saline and Acidic Media

The present work aims to provide corrosion performance data for an additively manufactured Ti6Al4V alloy in saline and polluted environments. The as-received additively manufactured material underwent heat treatment at 850 °C for 3 h to transform the acicular α' microstructure into a lamellar α microstructure. Comparative corrosion assessments were conducted between the heat-treated substrates, the as-received condition, and a conventionally mill-annealed alloy. Potentiodynamic polarization experiments were carried out in saline (3.5 wt.% NaCl) and acid aqueous media ((NH₄)₂SO₄ containing Harrison's solution). The corrosion performance of additively manufactured substrates matched or surpassed that of the conventional alloy in Harrison's solutions while remaining inferior in saline medium, despite forming a thicker passive film. Overall, the XY plane showed better corrosion performance, particularly after the elimination of the acicular α' martensite by the applied heat treatment. The results also suggested that the presence of the coarse β phase was beneficial in 3.5 wt.% NaCl solution and detrimental in Harrison's solutions, more so in acidified and fluorinated conditions.