Mechanism of alteration in passivity of additively manufactured Ni-Fe-Cr Alloy 718 caused by minor carbon variation

Unlike conventional alloys, where carbon content typically promotes carbide compound formation and reduces localized corrosion resistance, the impact of carbon in additively manufactured materials remains largely unexplored due to rapid cooling rates inhibiting carbide formation. This study addresses the novel question of whether reducing carbon content benefits corrosion performance and its underlying mechanisms in Ni-Fe-Cr-based alloy 718. Employing high-resolution techniques and microcapillary electrochemical methods, it was revealed that higher carbon content increases dislocation density at cell boundaries. This increased dislocation density facilitates the enhanced ejection of nickel and iron from the protective chromium oxide layer on the surface, leading to the formation of a defective outer Ni-Fe oxide layer. This compromised layer subsequently diminishes the alloy's corrosion resistance, particularly under tensile stress conditions.