We investigated the influence of chloride on the secondary passive film (SPF) on laser directed energy deposition Alloy 718 during electrochemical machining. The results show that SPF formed in chloride-containing electrolyte is more defective than that formed in chloride-free solution, due to the stepped-up cation ejection by chloride. Chloride accelerates the SPF failure via enhanced cation vacancy condensation, SPF dissolution and possibly via surface vacancy pairs’ coalescence, restraining the formation of CrO 3 and inducing a better surface quality than does the chloride-free electrolyte. Based on the Point Defect Model, a mechanism describing the influence of chloride on SPF was developed.
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