Corrosion Resistance Of AZ31 Research Articles

Investigations of microstructure and corrosion resistance of WC-Co and WC-Cr3C2-Ni coatings deposited by HVOF on magnesium alloy substrates

Magnesium alloys have found widespread application in various industries, mainly due to the combination of low density, the best structural material known today, and high strength to weight ratio. However, the use of magnesium alloys is limited due to their poor wear and corrosion behavior. In this study, two commercial powders, agglomerated and sintered WC-Co and WC-Cr3C2-Ni were thermally sprayed to deposit coatings onto two magnesium alloy substrates (AZ31 and AZ91) with a combination of two different spraying distances (320 and 400 mm). The main aim of this work was to investigate the microstructure and corrosion resistance of the coatings deposited by High Velocity Oxy Fuel (HVOF) spraying. The morphology and microstructure of the sprayed coatings were analyzed by Scanning Electron Microscopy (SEM) and X-ray diffraction (XRD). Additionally, porosity, microhardness and surface roughness were examined. Furthermore, potentiodynamic polarization was used to characterize the corrosion behavior of the deposited coatings. The experimental results showed that manufactured coatings are characterized by a dense microstructure with porosity typical for coatings sprayed with the HVOF method. Moreover small cracks and unmelted carbide particles embedded in the metal matrix were found in the as-sprayed coatings. Based on the results of the potentiodynamic studies it was found that the corrosion resistance of AZ31 and AZ91 magnesium alloys is not very high in a sodium chloride solution. The polarization resistance of AZ31 is very low (241.3 Ω∙cm2) and the corrosion current density is high (57.4 μA∙cm−2), whereas for AZ91 these values are 17.8 Ω∙cm2 and 1612.1 μA∙cm−2, respectively. The corrosion potential of the AZ31 and AZ91 alloy equal −1.56 V which is characteristic for magnesium alloys in a NaCl solution. For both type of substrates, better corrosion resistance has been obtained for the WC-Co coating. The Rp value was nearly 150 times higher than the one for uncoated AZ91 alloy, whereas for AZ31 the polarization resistance was about 17 times higher (Rp = 4.2 kΩ∙cm2) in comparison to non-covered alloy. In summary, all deposited coatings improved the corrosion resistance of the magnesium alloy. However, the WC-Co one protects the magnesium substrate against corrosion more effectively than the WC-Cr3C2-Ni.

An eco-friendly Ca[sbnd]Ce and Ca[sbnd]Y based LDH coating on AZ31 Mg alloy: Surface modification and its corrosion studies in simulated body fluid (SBF)

The corrosion resistance of AZ31 is inappropriate, which demands the improvement of the anti-corrosion performances for practical applications. Therefore, environmentally friendly rare earth elements based such as CaCe and CaY layered double hydroxide (LDH) coatings are developed on the AZ31 alloy surface in this work. The coatings are characterized by scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FT-IR), and the static sessile drop method as well as electrochemical measurements. The results show that these two kinds of LDH coating can obviously retard the corrosion of AZ31 in simulated body fluid (SBF). Also, precipitation of the corrosion products synergistically improves the self-healing and protection performances. However, the CaY based layers contain some cracks that limit the superior protection performance of the coating. The CaCe based LDH coating shows a significantly enhanced corrosion resistance with the corrosion current density of 0.058 μA·cm−2 which is prepared in the solution containing the Ca and Ce cations with the 2:1 mol ratio. It opens the possibility to improve the service life of AZ31 magnesium alloy in SBF.

Protective Performance of Plasma-Enhanced Chemical Vapor-Deposited Ethyl Cyclohexane Coating on Magnesium Alloys

In the present investigation, plasma-polymerized ethyl cyclohexane (ECH) coatings were deposited onto AZ31 and AM50 magnesium (Mg) alloys using plasma-enhanced chemical vapor deposition. The influences of deposition time on the coating formation, surface morphology, chemical composition and electrochemical corrosion behavior were investigated. The coating deposition was confirmed by infrared spectroscopy (FT-IR), and the thickness was measured using a scanning electron microscope. Energy-dispersive x-ray analysis revealed an increase in carbon and a decrease in Mg concentrations as the coating duration was increased. Electrochemical impedance spectroscopy (EIS) results confirmed an improvement in the corrosion resistance of AZ31 and AM50 alloys due to ECH coatings in the presence of a 3.5 wt.% NaCl solution. Further, equivalent circuit curve fitting analysis of the EIS results indicated an increase in charge transfer resistance (Rct) values with longer coating durations. These results confirmed the protecting ability of ECH coatings against corrosive ion attack, which was also substantiated by the surface morphologies after corrosion. Impedance values decreased as the duration of exposure in a NaCl solution increased, and the coating prepared using a 30-min ECH deposition exhibited better protection properties.

The Improvement of Durability of Biodegradable Magnesium Alloy by Using Bio-Inspired Coating

The observation of the natural world is increasingly inspiring the field of material science. A coating based on dopamine, the principle origin of the extraordinarily robust adhesion of the mussel to the solid surface, was used as an intermediate layer to decrease the degradation rate of a biodegradable device made of AZ31 magnesium alloy covered with an external organic coating. The dopamine-based film entailed a hydrophobic character to the sample, as confirmed by water contact angle test. The electrochemical analysis, made in Hank’s solution, showed that the bio-inspired film could improve the corrosion resistance of AZ31 when used together with an external organic coating.

Microstructure and Corrosion Properties of Homogenized AZ31 and AZ31+1%La Magnesium Alloys

Energy efficiency and decreasing emission of greenhouse gasses emerge that the importance of Mg alloys. Mg alloys can begin to supersede the steel and aluminum for structural applications, thanks to the developing of mechanical properties or corrosion resistance of Mg alloys. Rare earth metals such as Gd, Ce, Y and Nd have been utilized at AZ31 Mg alloys for this purpose in recent years. In this study, the effects of La addition and homogenization heat treatment on microstructure, hardness properties and corrosion resistance of AZ31 and modified AZ31 Mg alloys produced by low pressure die casting method were investigated.

Effect of Process Parameters on the Corrosion Resistance Properties of PEO Coatings Produced on AZ31B Magnesium Alloy

The automotive sector is particularly interested in magnesium alloys, which can decrease the weight of the vehicle leading to improved fuel efficiency and decreased emissions. However, poor corrosion resistance, especially in solutions containing chlorides, is a major limitation for its widespread exploitation in exposed automotive applications. Plasma electrolytic oxidation (PEO) coatings have been shown as a promising technology to improve the corrosion resistance of magnesium alloys 1. The properties of PEO synthesized coatings have been shown to significantly dependent on the process parameters employed to produce them2,3. Understanding the influence of process parameters on the overall corrosion resistance of AZ31 is essential if PEO technology is to be used in an industrial application. The present investigation examines the effect of processing time, current density, and electrolyte temperature on structural morphology of PEO coatings made on AZ31B linked to their corrosion resistance. PEO coatings were produced using a sodium silicate basic electrolyte using current densities ranging between 10 mA/cm2 and 20 mA/cm2. The temperature of the electrolyte was varied between 10-40ºC, while the processing time was varied between 15 and 30 minutes. The overall corrosion rate of PEO-coated samples was evaluated using mass loss testing and electrochemical impedance spectroscopy (EIS), while the composition and morphology of the PEO coatings were analyzed using a combination of x-ray diffraction (XRD), electron microscopy, and white light profilometry. The phase composition of the synthesized PEO coatings was analysed using XRD, see Figure 1. Spectra indicated that the PEO coating comprised two main phases, namely magnesium oxide (MgO) and forsterite (Mg2SiO4). The ratio between magnesium oxide and magnesium silicate was estimated via the reference intensity ratio (RIR) analysis. The mass ratio (MgO/Mg2SiO4) for PEO coatings made on AZ31B decreased from 0.63 (10 mA/cm2) to 0.11 (20 mA/cm2). The observed increase in the weight fraction of forsterite when higher current densities were is related to polymerization of silicate ions during the deposition process. It has been previously reported that the extremely high energy generated by the plasma discharges promote polymerization of the silicate4. Increasingly favorable polymerization resulted in greater incorporation of silicates into the coating, ultimately leading to higher weight fraction of forsterite and lower weight fraction of magnesium oxide. The corrosion rates of the two coated specimens (10 mA/cm2 and 20 mA/cm2) in addition to the bare metal AZ31 substrate were measured by 5-day mass loss testing in a 0.086M NaCl solution, see Figure 2. Both PEO coatings exhibited significantly improved corrosion resistance properties compared to as-received AZ31. The corrosion rates of coatings produced using an applied current density of 10 mA/cm2 were significantly lower than those of coating produced using a current density of 20 mA/cm2. The current research effort is focusing on providing explanations for observed differences in corrosion resistance properties of PEO produced when applying different current density values. The effect of changes in processing time and electrolyte temperature is also under investigation.

Atmospheric pressure plasma enhanced chemical vapor deposition of SiOx films for improved corrosion resistant properties of AZ31 magnesium alloys

Abstract This study investigated the feasibility of using atmospheric pressure plasma enhanced chemical vapor deposition (APPECVD) system using tetraethoxysilane (TEOS)/O 2 plasma to deposit SiO x films as anti-corrosion layer on the AZ31 magnesium alloys. SiO x films were characterized by a scanning electron microscopy (SEM), transmission electron microscopy (TEM), Fourier-transform infrared spectroscopy (FTIR) to study the surface morphology, and composition. In addition, the corrosion protection afforded by such thin films was investigated by electrochemical techniques, and relationships among composition, structure, and electrochemical properties of these films are reported. The results showed that deposition of silica-like dense film at an O 2 carrier gas flow rate of 1800 sccm represented a near stoichiometric composition of O/Si ratio (2.0) and a lower degree of porosity, while silicone-like film with an O/Si ratio of 3.7 and higher degree of porosity was obtained at 600 sccm. The potentiodynamic polarization tests show that both SiO x films coated on AZ31 alloys have more positive corrosion potential and lower corrosion current density than AZ31 substrates, indicating the corrosion resistance of AZ31 can be improved by depositing SiO x film on its surface. In particular, as the surface is more compact and cross-linked, the silica-like film has a better corrosion resistance than the silicone-like film.

Nano Hydroxyapatite as a Corrosion Resistant Coating of AZ31 Magnesium Alloys

nanohydroxyapatite (n-HAP) was coated on to AZ31 magnesium alloy in order to reduce the surface corrosion rate and enhance the bio-compatibility. N-HAP was successfully coated by pulse electrodeposition technique. Morphology and composition of the coatings were investigated by scanning electron microscopy and X-ray diffraction methods, respectively. The corrosion behaviors of the coatings were studied by tafel polarization and impedance spectroscopy tests. Results demonstrated that the porosity of the nanostructure coating decrease in comparison with micro structure coating and therefore, corrosion resistance of AZ31 was improved significantly. Also, the adhesion of nanostructure coating was increased and thus it can be introduced as a suitable coating for body implants.

Recent Studies on Coating of some Magnesium Alloys; Anodizing, Electroless Coating and Hot Press Cladding

In the present study, coating of some magnesium alloys including AZ31 and AZ91 were studied using different techniques namely anodizing, electroless and hot press cladding. AZ91 alloy was coated using anodizing process using three types of environmental friendly electrolytes; the first based on sodium silicate, the second based on sodium hydroxide-boric acid-borax and the third on sodium silicate-potassium hydroxide-sodium carbonate-sodium tetra borate. Characterization of the anodizing layer was achieved by determination of surface morphology, microstructure, phase analysis, coat thickness, adhesion and corrosion resistance. It was found that the anodic film thickness increases with increasing the current density, anodizing voltage and deposition time until the deposition stops due to the formation of a thick anodic film. The range of the anodic film thickness is 28 42 µm.Optimization of the anodizing conditions - current density and deposition time was determined for each electrolyte. A corrosion efficiency ranging from 94% to 97% was reached; the highest value corresponding to the third electrolyte. Another study is the electroless Ni plating technique with zinc pre-treatment applied on several magnesium alloys and the effect of pre-treatment and post heat treatment on the coat characteristics. The surface morphology, surface roughness, thickness of the layer, EDX analysis, adhesion, hardness and corrosion resistance are covered in this part. The electroless layer thickness is about 6 µm. The results showed good bond quality of the coat maintaining good corrosion behaviour of electroless Ni-P based on potentiodynamic polarization tests in chloride solution where it was improved after heat treatment process. On the other hand, AZ31 was covered by a commercial pure aluminum sheet by hot pressing. The influence of the applied pressure, holding time and temperature on the bond characteristics was studied. The experimental investigation has revealed a good bond quality due to the effective mutual diffusion of Mg and Al. The phase analysis resulted in the formation of two equilibrium phases namely; Mg17Al12and Mg2Al3. The corrosion resistance of AZ31 is enhanced as a results of this process by 98.6%. Further points will be covered.Keywords: Magnesium alloys; Coating; Anodizing; Electroless; Hot press cladding; environmental friendly electrolytes; corrosion

Phosphate film free of chromate, fluoride and nitrite on AZ31 magnesium alloy and its corrosion resistance

A phosphate solution free of chromate, fluoride and nitrite was prepared and an environment-friendly film was obtained on AZ31 magnesium alloy surface via the chemical deposition method. The morphology, composition, phase structure and its corrosion resistance were studied. The effects of film-forming temperature and free acid on corrosion resistance, microstructure and electrochemical behavior of the film were discussed. The results indicate that the corrosion resistance of AZ31 with the phosphate film was better than blank AZ31 substrate, which was most attributed to the great inhibitive action on the anodic dissolution and cathodic hydrogen evolution of the film.

On corrosion behaviour of magnesium alloy AZ31 in simulated body fluids and influence of ionic liquid pretreatments

This paper reports on the corrosion of Mg alloy AZ31 in simulated body fluid (SBF) using static immersion tests and electrochemical impedance spectroscopy. A preliminary study on the effect of flowing SBF on the corrosion behaviour of AZ31 has also been carried out. Low toxicity ionic liquids (ILs) trimethyl(butyl)phosphonium diphenyl phosphate P1444DPP and trihexyl(tetradecyl)phosphonium bis-2,4,4trimethylpentyl-phosphinate [P66614][i(C8)2PO2] have been used to provide corrosion protection for AZ31 in SBF. Time dependent immersion tests indicate that under static conditions, AZ31 suffers severe localised corrosion in SBF, with pits developing predominantly beside the Al–Mn intermetallic phase in the α matrix. At longer immersion times, the corrosion product eventually precipitates and covers the entire specimen surface. When exposed to SBF under flowing conditions with a shear stress of 0·88 Pa, more uniform corrosion was observed. The optical profilometry results and electrochemical impedance spectroscopy analysis suggest that both P1444DPP and [P66614][i(C8)2PO2] pretreatments can increase the corrosion resistance of AZ31 in SBF, in particular by decreasing the number of deeper pits found on the alloy surface. Cytotoxic test shows that the presence of the ILs P1444DPP and [P66614][i(C8)2PO2] in cell culture media slightly inhibits the growth of human coronary artery endothelial cells in comparison with the good cell viability around the treated specimen. A pretreatment with IL is used in order to improve the corrosion resistance of this alloy in SBF.

Influence of Silane on Corrosion Performance of Silane-Modified Acrylate Interpenetrating Polymer Network Coating on Magnesium Alloy AZ31

The possibility that various silane treatments may enhance the corrosion resistance of a magnesium alloy AZ31 with silane-modified acrylate interpenetrating polymer network (IPN) coating has been investigated. Potentiodynamic electrochemical tests and neutral salt spray test were applied to evaluate the corrosion performance of the alloy. The results show that silane film improves corrosion resistance of the AZ31 alloy with and without IPN coating. The silane-modified IPN coatings improved more than 4 orders of magnitude of the corrosion resistance of the substrate.

Corrosion behaviour of Mg-Al alloys with Al-11Si thermal spray coatings

The corrosion resistance of AZ31, AZ80 and AZ91D Mg–Al alloys with Al–11Si thermal spray coatings was evaluated by electrochemical and gravimetric measurements in 3.5 wt% NaCl solution. The changes in the morphology and corrosion behaviour of the Al–11Si coatings induced by a cold-pressing post-treatment under 32 MPa were also examined. The as-sprayed Al–11Si coatings revealed high degree of porosity and poor corrosion protection, which resulted in galvanic acceleration of the corrosion of the magnesium substrates. The application of a cold-pressing post-treatment produced more compact Al–11Si coatings with better bonding at the substrate/coating interface and slightly higher corrosion resistance. However, interconnected pores remained in the cold-pressed coatings due to the low plasticity of the Al–11Si powder and galvanic corrosion of the substrate was observed after immersion in 3.5 wt% NaCl for 10 days.

Comparison of corrosion behaviors of AZ31, AZ91, AM60 and ZK60 magnesium alloys

The corrosion behaviours of four kinds of rolled magnesium alloys of AZ31, AZ91, AM60 and ZK60 were studied in 1 mol/L sodium chloride solution. The results of EIS and potentiodynamic polarization show that the corrosion resistance of the four materials is ranked as ZK60>AM60>AZ31>AZ91. The corrosion processes of the four magnesium alloys were also analyzed by SEM and energy dispersive spectroscopy(EDS). The results show that the corrosion patterns of the four alloys are localized corrosion and the galvanic couples formed by the second phase particles and the matrix are the main source of the localized corrosion of magnesium alloys. The corrosion resistance of the different magnesium alloys has direct relationship with the concentration of alloying elements and microstructure of magnesium alloys. The ratio of the β phase in AZ91 is higher than that in AZ31 and the β phase can form micro-galvanic cell with the alloy matrix, as a result, the corrosion resistance of AZ31 will be higher than AZ91. The manganese element in AM60 magnesium alloy can form the second phase particle of AlMnFe, which can reduce the Fe content in magnesium alloy matrix, purifying the microstructure of alloy, as a result, the corrosion resistance of AM60 is improved. However, due to the more noble galvanic couples of AlMnFe and matrix, the microscopic corrosion morphology of AM60 is more localized. The zirconium element in ZK60 magnesium alloy can refine grain, form stable compounds with Fe and Si, and purify the composition of alloy, which results in the good corrosion resistance of ZK60 magnesium alloy.

Formation by reactive magnetron sputtering of TiN coating on Ti-implanted magnesium alloy

Reactive magnetron sputtering method was used to deposit TiN coating on Ti-implanted magnesium alloy. FESEM, GIXRD and AES were used to investigate this surface system's micro-morphology, crystalline structure and chemical composition, respectively. It showed that TiN coating took on a compact surface morphology and existed as a columnar crystalline structure. The results of the electrochemical test and immersion test showed that the corrosion resistance of AZ31 was greatly improved in 3.5 wt.% NaCl solution by this kind of surface treatment technique. It was mainly due to the combined effect of the dense TiN coating, the Ti-implanted layer and the good adhesion between coating and substrate.

Al Arc Spray Coating on AZ31 Mg Alloy and Its Corrosion Behavior

Aluminum arc spray process was employed to form an aluminum coating on AZ31 magnesium alloy substrate. Anti-corrosion property of the Al-coated specimens was evaluated by salt immersion tests and electrochemical tests. There was no apparent inter-layer diffusion or compound layer formation between the aluminum coating and the substrate under as-sprayed condition. To improve the density of the coating and the bonding strength between the coating and the substrate, a heat treatment process was conducted after spraying to form an interlayer by metallurgic diffusion. The interlayer consisted of large primary crystal Mg17Al12 phase and minute lamella structure that consisted of Mg17Al12 and α-Mg. The hardness of both the aluminum coating and the interlayer are higher than that of the substrate. In electrochemical experiments, the corrosion current density decreased from 2.4×10-1mA/cm2 of AZ31 to 7.1×10-3mA/cm2 of heat-treated specimen. It suggests that the corrosion resistance of AZ31 can be greatly improved by aluminum arc spray with a following heat treatment process.