Synergism of Arc Spraying, Laser Processing, and Hydrophobization for Long‐Lasting Corrosion Protection of MA8 Magnesium Alloy

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Due to a number of unique properties, magnesium and its alloys are attractive for use in mechanical engineering, medicine, aviation, the automotive industry, etc. Unfortunately, the widespread use of these materials is limited by their low corrosion resistance. Traditional surface modification techniques have struggled to simultaneously enhance both the mechanical durability and corrosion resistance of magnesium‐based materials. Herein, a method synergistically combining the advantages of arc spraying, laser processing, and hydrophobization is developed. This finely tuned combination results in the production of an aluminum coating with superhydrophobic properties formed on top of magnesium alloy that has very high mechanical and chemical resistance. The results presented in this article demonstrate that such coatings preserve a constant contact angle exceeding 165° during a year of laboratory storage, withstand long‐lasting humid and salt fog atmosphere, demonstrate corrosion current lower than 3 × 10−8 A cm−2 during 120 days of its continuous contact with chloride‐containing corrosive environments, and preserve the superhydrophobic state after sand abrasion test. The corrosion inhibition mechanisms of the designed coating are discussed. The developed innovative approach addresses a critical challenge in enhancing the corrosion resistance of magnesium‐based materials, paving the way for their broader application across various industrial sectors.