Enhanced corrosion protection of AZ31 magnesium alloy by duplex plasma electrolytic oxidation and polymer coatings

The corrosion behaviour of an AZ31 magnesium alloy coated with plasma electrolytic oxidation (PEO), polymer and a combination of them was assessed by electrochemical impedance spectroscopy (EIS) in 0.1M NaCl solution. The polymer coating was applied on a just cleaned surface (without any special preparation) and also on PEO treated magnesium substrate. While the polymer coated and the mere PEO treated magnesium alloy specimens lasted less than 50 h in the EIS tests, the specimens with the duplex coating (PEO+polymer) successfully resisted 1000 h in the EIS tests without showing any degradation. The improved adhesion of the polymer coating in presence of the PEO layer and the effective sealing of the pores in the PEO coating with the polymer were responsible for the enhanced corrosion resistance. The synergistic beneficial effect of the duplex coatings on the corrosion behaviour was also witnessed in the salt spray tests.