The DurAMat project advanced significantly on the scientific front, achieving substantial progress across additive manufacturing (AM), corrosion science, mechanical performance, and process–structure–property modelling. In WP1, the consortium produced and characterized WAAM-repaired aluminium, carbon steel, stainless steel, and nickel-based alloys, establishing correlations between microstructural defects (e.g. porosity, inclusions, residual stresses) and corrosion behaviour, while mechanical testing of multi-material WAAM walls demonstrated promising strength and ductility, supported by the development of a thermodynamically informed modelling framework and customized multi-wire deposition hardware enabling functionally graded materials. In WP2, AM-fabricated duplex stainless steels was produced and evaluated, revealing distinct polarization, hydrogen uptake, and SCC responses linked to microstructure; complementary studies established early process–structure–property relationships for WAAM-processed Mg alloys, including newly developed methodologies to quantify localized corrosion using profilometry and image analysis. Parallel work on AM metallic coatings successfully optimized certain coatings on 316L and Corrax substrates, with preliminary electrochemical testing indicating localized elemental depletion as a key degradation mechanism. Collectively, these activities delivered the first integrated dataset on AM metals and coatings produced within DurAMat, validated laboratory and industrial-scale test protocols, and generated foundational understanding of degradation mechanisms and mechanical integrity that will underpin the next phase of model development, optimization, and exploitation.
