Improvement of Corrosion Resistance of Binary Mg-Ca Alloys Using Duplex Aluminum-Chromium Coatings

Al-AlCr was coated on Mg-Ca and Mg-Zn-Ce-La alloys using physical vapor deposition method. The surface morphology of the specimens was characterized by x-ray diffraction, scanning electron microscopy equipped with energy-dispersive x-ray spectroscopy, and atomic force microscopy (AFM). The AFM results indicated that the average surface roughness of Al-AlCr coating on the Mg-Ca alloy is much lower than that of Al-AlCr coating on the Mg-Zn-Ce-La alloy. However, Al-AlCr coating on the Mg-Ca alloy presented a more compact structure with fewer pores, pinholes, and cracks than Al-AlCr coating on the Mg-Zn-Ce-La alloy. Electrochemical studies revealed that the novel coating (Al-AlCr) can remarkably reduce the corrosion rate of the Mg-Ca alloy in 3.5 wt.% NaCl solution. It was seen that the anodic current density of the Al-AlCr-coated Mg-Ca alloy was very small when compared to the Al-AlCr-coated Mg-Zn-Ce-La and uncoated alloys. Impedance modulus (Z) of the Al-AlCr-coated samples was higher than that of the bare Mg alloys. Z of Al-AlCr-coated Mg-Ca alloy was higher than that of the Al-AlCr-coated Mg-Zn-Ce-La alloy at low frequency.