The different chrome-free chemical conversion coatings were prepared on AZ91D
magnesium alloy and SEM was used to observe the surface. The corrosion behaviors of die-casting
AZ91D magnesium alloy with different coating in chloride environment were investigated by
hydrogen gas evolution in immersion test, salt spray test and electrochemical measurement. The
results showed that the corrosion resistance of magnesium alloy treated with two-step chemical
conversion and sealing was the highest and was comparable with that of chromating, and followed
by two-step chemical conversion treatment without sealing. The one-step chemical conversion
treatment had the lowest corrosion resistance. Polarization and EIS characteristics in 5% NaCl
solution depended on the type of surface treatment and correlated well with the order of corrosion
resistance. Contrasted with one-step chemical conversion coating, the coating of two-step chemical
conversion with sealing on magnesium alloy had more excellent corrosion resistance because the |Z|
increased, the corrosion area was decreased and the time of the first pitting occurrence was
prolonged. It is expected that this experiment can provide a foundation for designing more super
chemical conversion coating to replacing the chromate conversion.