Al-Mn coating electrodeposited from ionic liquid on NdFeB magnet with high hardness and corrosion resistance

Al-Mn coatings were electrodeposited on sintered NdFeB permanent magnet in MnCl2-AlCl3-1-ethyl-3-methylim-idazolium chloride (MnCl2-AlCl3-EMIC) ionic liquid at room temperature. The coatings were characterized by scanning electron microscope (SEM), energy dispersive spectroscopy (EDS) and X-ray diffraction (XRD). The adhesion strength of the coating on NdFeB substrate was evaluated by thermal shock and scratch test. The hardness and corrosion behavior of Al-Mn coating were measured by a Knoop microhardness tester, immersion test and neutral salt spray test respectively. The results showed that the amorphous structure of the deposits was obtained at the current density of 6 mA/cm2, while higher current densities resulted in a mixed structure of amorphous and crystalline. The Al-Mn coating showed excellent adhesion strength on NdFeB substrate with the thermal shock test over 30 cycles and Lc > 80 N. The hardness of Al-Mn coating was up to 5.4 GPa. The amorphous Al-Mn coating showed an anodic sacrificial protection with a low corrosion rate for NdFeB. Meanwhile, the magnetic properties measured by an AMT-4 magnetic measurement device showed that Al-Mn coating did not deteriorate the magnetic property of NdFeB.