The Corrosion Behaviour of Additively Manufactured AlSi10Mg Parts Compared to Traditional Al Alloys

Additive manufacturing of metal parts in the motorsport industry is becoming a decisive technology for producing lightweight and rigid parts, with increasing applications as the costs decrease. Among the available metal alloys, AlSi10Mg is one of the most widely used. In this paper, the corrosion resistance of additively manufactured AlSi10Mg is compared with that of other traditionally manufactured aluminium alloys widespread in the automotive industry. Several potentially corrosive agents, typical of vehicle applications, were used: salty water, motor oil, suspension oil, cooling fluid and gasoline. Corrosion tests were conducted at both room temperature and 90 C. The effects of heat and surface treatments were evaluated separately. The samples were visually inspected and weighed to evaluate the corrosion rate with the aid of SEM and EDS analysis. Additively manufactured AlSi10Mg generally showed better corrosion resistance in the stress-relieved condition as compared to the T6-treated state, with slightly better results for the polished samples. Motor oil, suspension oil, cooling fluid and gasoline did not significantly corrode the specimens, except for the T6-treated AlSi10Mg samples at 90 C. However, the corrosion rate was always higher than traditionally manufactured aluminium alloys tested for comparison.