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September 12, 2025Anti-Corrosion Methods and Materials1 citations

Effect of silicon content on the mechanical and corrosion behavior of additively manufactured aluminum–silicon alloys via selective laser melting

YSYong ShiUniversity of Nottingham Ningbo China HTHsiao Wei TanUniversity Malaya Medical Centre LXLiuqi XieLanzhou Jiaotong University

Key Points

Higher silicon content significantly improved the tensile strength of aluminum-silicon alloys, reaching up to 500 MPa.
Electrochemical tests indicate that increased silicon levels enhance corrosion resistance by shifting the open-circuit potential to more positive values.
The methodology employed included tensile tests, scanning electron microscopy, and corrosion evaluation in saline solution.
Findings point to a coupling effect of silicon content, influencing microstructure, mechanical properties, and corrosion behavior in SLM-processed alloys.

Abstract

Purpose The purpose of this study is to investigate the effects of silicon (Si) content on the mechanical properties and corrosion behavior of additively manufactured aluminum-silicon (Al-Si) alloys and to provide composition and process schemes for high-performance alloys. Design/methodology/approach Samples with different Si contents (7%, 10%, 12%) were prepared by selective laser melting (SLM). Mechanical properties were tested via tensile tests, while microstructures were observed using scanning electron microscopy and energy-dispersive X-ray spectroscopy. Corrosion behavior was evaluated through electrochemical tests in 3.5 Wt.% NaCl solution and surface morphology analysis. Findings Increasing Si content refined the melt pool morphology, improved the continuity of Si networks and enhanced tensile strength (up to 500 MPa for AlSi12Mg0.5). Electrochemical results showed that higher Si content shifted the open-circuit potential to become more positive, increased oxide film resistance and reduced corrosion current density, indicating better corrosion resistance. The corrosion mechanism was dominated by pitting, with Al matrix dissolution around Si networks. Originality/value This work systematically reveals the coupling effect of Si content on microstructure–mechanical properties–corrosion behavior in SLM-processed Al-Si alloys, offering a basis for designing high-strength and corrosion-resistant Al-Si alloys for aerospace and marine applications.

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