The influence of sensitisation heat treatment, surface roughness and repetitive cyclic voltammetry (RCV) procedure (that was used to create passive films on the surface of sensitised samples) on the corrosion behaviour of UNS S31803 duplex stainless steel was evaluated using sodium hydroxide etching, double-loop electrochemical potentiodynamic reactivation (DLEPR), potentiodynamic polarisation, Mott–Schottky analysis, X-ray diffraction and optical microscopy techniques. The results showed that prolonged sensitisation time leads to the formation of defective passive films on the surface. In addition, as the substrate surface roughness decreases, the defect concentration in the resulting passive film decreases. Moreover, thick passive films that were created at a high number of RCV cycles contain fewer defects than the thin ones. Finally, the specimens with smooth surfaces, thick passive films and low degree of sensitisation exhibit high corrosion resistance due to their intact passive layers formed on their surfaces.

Additive manufacturing (AM) is a rapidly evolving technology that enables the fabrication of complex 3D components across a wide range of materials and applications. Among various AM techniques, direct energy deposition (DED) has gained significant attention for its ability to produce metal and alloy components with moderate geometric complexity while maintaining a high deposition rate. This makes DED particularly suitable for real-world applications, including in-situ repair and restoration of metallic parts. Due to the nature of the DED process, components undergo extreme heating and cooling cycles, leading to microstructural evolution, process-induced defects, and variations in properties. While extensive research has explored the microstructure and mechanical properties of DED-fabricated alloys, studies on their surface degradation remain incomplete. Corrosion behavior has been well documented, given its significance in AM alloys; however, their tribological performance remains largely unexplored. This paper provides a comprehensive review of the wear behavior of DED-manufactured alloys, emphasizing the potential of DED technology for producing durable components. Specifically, it examines the wear characteristics of four key material groups—Fe-based, Ni-based, Ti-based, and Cu-based alloys—by summarizing existing studies and analyzing the underlying mechanisms influencing their wear resistance. Finally, the paper identifies research gaps and outlines future directions to advance the understanding of wear performance in DED alloys, paving the way for further innovation in this field.

In the present work, the effect of sensitization heat treatment on the intergranular corrosion (IGC) behavior of AISI 410 martensitic stainless steel was investigated using potentiodynamic electrochemical impedance spectroscopy (PDEIS) in conjunction with conventional methods including acid etching test, anodic potentiodynamic polarization, double-loop electrochemical potentiodynamic reactivation (DLEPR) and electrochemical noise (EN). Microstructural studies by scanning electron microscopy revealed that increasing tempering time up to 2h would be followed by more severe localized attack, but desensitization state attributed to specimens undergone prolonged tempering cannot be interpreted based on the standard test method. Susceptibility to IGC via DLEPR experiments indicates differences in the degree of sensitization (DOS) of specimens with varying tempering time, revealing a healing effect arising from prolonged tempering. The EN results elucidated the alloy tendency for active dissolution, but no obvious correlation can be established between the EN results and IGC behavior. The PDEIS data clarified that the charge transfer resistance values related to the AC responses in the middle of transpassive potential region can be utilized to investigate and compare the IGC susceptibility of the alloy. Moreover, the surface morphology of corroded samples under such experimental conditions can be used to qualitatively compare the severity of intergranular attack.