Effect of SiO2-reinforcement and alkali treatment on the corrosion resistance of plasma electrolytic oxide coating on AZ31 magnesium alloy

Plasma electrolytic oxidation (PEO) produces an oxide coating containing pores and cracks lowering corrosion protection. The defects can be sealed by in-situ or post-treatment methods. This work compares the sealing effect of SiO₂ particles and post-alkali treatment on the corrosion resistance of PEO coatings formed on AZ31 magnesium (Mg) alloy. PEO was conducted in a phosphate-based electrolyte containing 2 g/l nanoparticle SiO₂ at a constant current density of 300 A/m² for 10 min. The post-alkali treatment was performed in 0.5 M NaOH solution at 80 °C for 30 min. The corrosion resistance was evaluated using polarization, electrochemical impedance spectroscopy, and weight loss tests. The SiO₂ particles were successfully embedded uniformly in the Mg₃(PO₄)₂ coating, enhancing the coating compactness and stability. The reinforced coating exhibited ten times higher impedance modulus and lower corrosion current density. The post-alkali treatment improved corrosion resistance but not as high as the SiO₂ reinforcement. The impedance modulus of the alkali-treated specimen increased five times, and the corrosion current density decreased three times of the base coating. The weight loss test consistently showed that the SiO₂-reinforced coating generated lower mass loss during 14 days of immersion in simulated body fluid.