Microstructure, corrosion resistance and formation mechanism of alumina micro-arc oxidation coatings on sintered NdFeB permanent magnets

Alumina ceramic coatings were prepared on the sintered NdFeB magnets by micro-arc oxidation (MAO) in aluminate solution. The effects of anodic voltages on the microstructure and corrosion resistance of the coatings were investigated and the formation mechanism of the coating was also detailedly discussed. The microstructure and composition of the MAO coatings were characterized by SEM, XRD, EDS, XPS and surface roughness, respectively. The MAO coatings on NdFeB magnets were mainly composed of Al2O3 crystal phase, and Fe2O3 and Nd2O3 amorphous phase with some absorbed H2O and -OH. With increasing the voltages, the crystallinity of Al2O3 phase enhanced, while the surface roughness of the coatings also increased. At the same time, the pore sizes of MAO coatings increased, while the amount of the pores decreased. The corrosion resistance of NdFeB samples was improved due to the existence of the MAO coatings. With increasing the voltages, the corrosion resistance of the coated NdFeB samples increased first, reaching the optimum at 420 V, and then decreased. The corrosion protection efficiency of the coatings could be up to 94.3%. At the initial stage of MAO process, the compact barrier layer of NdFeB magnets was formed through the deposition of the electrolyte, which was the critical procedure for the MAO treatment of NdFeB magnets and the biggest difference from the valve metals through the conventional anodizing.