High corrosion resistance multilayer nickel coatings on AZ91D magnesium alloys

Abstract

The multilayer coatings consisting of electroless Ni–P, Ni–P–ZrO2 and electroplating Ni coatings were investigated. The surface and cross-section morphologies of coatings were observed with SEM. The microstructures were analysed by XRD. The corrosion resistance was evaluated by potentiodynamic polarisation curves and salt spray tests. The results showed that the electroplating Ni coating was crystal structure, whereas the electroless Ni–P and Ni–P–ZrO2 coatings displayed amorphous characteristic. The electroplating Ni coating exhibited more positive corrosion potential Ecorr and lower corrosion current density Icorr than that of electroless Ni–P and Ni–P–ZrO2 coatings. The samples covered with multilayer coatings of Ni–P–ZrO2/Ni/Ni–P (from substrate to surface) indicated the best corrosion resistance among six samples, and the salt spray tests were carried out for more than 1000 h. According to the analysis of corrosion mechanism, the upper Ni–P layer served as sacrificial protection anode due to its more negative corrosion potential Ecorr in comparison with the middle electroplating Ni layer. When the upper Ni–P layer was consumed, the middle Ni layer went to prevent from corroding. Until the corrosion pits penetrated all of the protective coatings, the substrate of magnesium alloys was destroyed completely.