Influence of second phase on corrosion performance and formation mechanism of PEO coating on AZ91 Mg alloy

Plasma electrolytic oxidation (PEO) treatment has been performed on AZ91 Mg alloy in a silicate-containing alkaline electrolyte to disclose the relationship between second phase and resultant coating. The morphology and corrosion behavior were characterized for PEO coatings on three different AZ91 substrates with microstructures altered by heat treatment. In the presence of β phase, both the substrate and PEO coating exhibit enhanced corrosion resistance with finer and more evenly distributed β phase precipitates. In the as-cast AZ91, the anodized coating displays chemically and morphologically discontinuity on α and β phase with very coarse and defective regions on two-phase boundaries. In aged AZ91 with nano-sized β phase precipitates, the PEO coating shows no obvious difference on two-phase boundaries and is more homogenous with fewer pores and defects. The residual stress values given by X-ray diffraction (XRD) analysis indicate that PEO coating on aged AZ91 with finest β phase has the smallest stress which might be the reason for its improved corrosion resistance under synergetic effect of corrosive ions and residual stress. Conversely, in the absence of β phase, i.e. after solid solution treatment, the coating is characterized by the most inhomogeneous microstructure and the worst corrosion resistance, presumably owing to the absence of protective aluminum-containing oxides in the coating and more severe localized oxidation behavior adjacent to AlMn phase. Understanding the effect of second phase on PEO coating will enable us to optimize porous oxide structures for improved corrosion resistance by properly altering the substrate microstructure.