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<p>Hybrid alloy structures manufactured by combining additive manufacturing (AM) with conventional manufacturing techniques have developed as a versatile approach to fine-tune microstructure, improve mechanical performance, and ensure localized characteristics control in certain regions of engineering parts. It is recognized that this manufacturing synergy is beneficial for structural alloys opened to harsh environments, in which corrosion activity is a paramount performance metric. This review consolidates the latest understanding of corrosion performance of hybrid alloys developed by techniques such as selective laser melting, directed energy deposition, casting, forging, and welding, focusing on how processing, microstructure, and electrochemical performance are interconnected. Important features emphasized comprises of the impact of interfacial bonding quality, residual stresses, heat-affected zones, and compositional gradients on corrosion mechanisms. Understanding from the experimental analysis of open-circuit potential, potentiodynamic polarization, electrochemical impedance spectroscopy, and post-corrosion microstructural analyses is critically evaluated. Also, focus will be directed to how microstructural variability at the AM-conventional interface controls localized corrosion susceptibility, passive film stability, and long-term integrity. Lastly, the review points on current research gaps and identifies future directions, emphasizing advanced characterization techniques, real-time corrosion monitoring, and predictive modeling to better understand and develop the microstructure–property–performance connection in hybrid alloy structures as prevalently used in aerospace, automotive, and marine industries.</p> Graphical Abstract <p></p>

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A Review on Corrosion Behavior of Hybrid Alloy Structures via Additive–Conventional Manufacturing: Microstructure–Property–Performance Relationships

  • 期刊论文

  • 发表日期：

    2026年7月11日

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  • Samson Dare Oguntuyi,
  • Mandlenkosi G. R. Mahlobo,
  • Kasongo Nyembwe,
  • Peter M. Mashinini,
  • Mxolisi B. Shongwe,
  • Peter A. Olubambi

摘要

Hybrid alloy structures manufactured by combining additive manufacturing (AM) with conventional manufacturing techniques have developed as a versatile approach to fine-tune microstructure, improve mechanical performance, and ensure localized characteristics control in certain regions of engineering parts. It is recognized that this manufacturing synergy is beneficial for structural alloys opened to harsh environments, in which corrosion activity is a paramount performance metric. This review consolidates the latest understanding of corrosion performance of hybrid alloys developed by techniques such as selective laser melting, directed energy deposition, casting, forging, and welding, focusing on how processing, microstructure, and electrochemical performance are interconnected. Important features emphasized comprises of the impact of interfacial bonding quality, residual stresses, heat-affected zones, and compositional gradients on corrosion mechanisms. Understanding from the experimental analysis of open-circuit potential, potentiodynamic polarization, electrochemical impedance spectroscopy, and post-corrosion microstructural analyses is critically evaluated. Also, focus will be directed to how microstructural variability at the AM-conventional interface controls localized corrosion susceptibility, passive film stability, and long-term integrity. Lastly, the review points on current research gaps and identifies future directions, emphasizing advanced characterization techniques, real-time corrosion monitoring, and predictive modeling to better understand and develop the microstructure–property–performance connection in hybrid alloy structures as prevalently used in aerospace, automotive, and marine industries.

Graphical Abstract