Effect of (NaPO3)6 concentrations on corrosion resistance of plasma electrolytic oxidation coatings formed on AZ91D magnesium alloy

Different plasma electrolytic oxidation (PEO) coatings were prepared on AZ91D magnesium alloy in electrolytes containing various concentrations of (NaPO₃)₆. The morphologies, chemical compositions and corrosion resistance of the PEO coatings were characterized by environmental scanning electron microscopy (ESEM), X-ray diffractometer (XRD), energy dispersive analysis of X-rays (EDAX), potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) test. The results showed that the PEO coatings were mainly composed of MgO, Mg₂SiO₄, MgAl₂O₄ and amorphous compounds. As the (NaPO₃)₆ concentrations increased from 0 to 10 g/l, the thickness and surface roughness of the coatings approximately linearly increased; the MgO and Mg₂SiO₄ phase increased within the concentration range of 0–3 and 0–5 g/l, and then decreased within the range of 3–10 and 5–10 g/l, respectively, while the MgAl₂O₄ phase gradually decreased. Moreover, the corrosion resistance of the coatings increased within the range of 0–5 g/l and then decreased within the range of 5–10 g/l. The best corrosion resistance coating was obtained in electrolyte containing 5 g/l (NaPO₃)₆, it had the most compact microstructure. Besides, a reasonable equivalent circuit was established, and the fitting results were consistent with the results of the EIS test.