Investigation on Improving the Hot Corrosion Resistance of Selective Laser Melting Manufactured Inconel 625 by Pre-Oxidation Heat Treatment

The present study was focused on assessing the molten salt-induced hot corrosion resistance of selective laser melting (SLM) manufactured Inconel 625 at 900 °C for 96 h and investigating the possibility of improving the superalloy's corrosion resistance by applying a pre-oxidation heat treatment. The material's hot corrosion properties were assessed in a heat-treated state (heat treatments performed at 1000 °C/1 h and 1150 °C/1 h, respectively) with and without pre-oxidation. The heat treatment at 1000 °C promoted the columnar dendrite morphology evolution, while the heat treatment at 1150 °C promoted the equiaxed dendrite morphology evolution. At 1150 °C, microstructural features specific to conventional manufactured material developed (annealing twin boundaries). They are considered a sign of anisotropy reduction due to equiaxed grains forming and it is believed that the internal stress in the material is reduced. High-temperature pre-oxidation heat treatment at 900 °C for 96 h ensured the formation of protective oxide scales with a reduced thickness (1.74 μm in the case of samples' heat-treated at 1000 °C, and 2.22 μm in the case of samples' heat-treated at 1150 °C, respectively). Experimentally, based on weight gain and oxide scale analysis, it was proven that pre-oxidation can improve the hot corrosion resistance of SLM manufactured Inconel 625 by forming a stable and protective oxide scale on the surface of the alloy before exposure to molten salts. The preformed oxide layer acts as a barrier for the corrosive species, reducing the formation of detrimental compounds, especially Mo-rich sulfides. Based on the tests, an improvement in corrosion resistance of up to 33.94% was observed in samples heat-treated at 1150 °C with pre-oxidation compared to samples heat-treated at 1000 °C without pre-oxidation.