Characterization of Composite Coatings Produced by Plasma Electrolytic Oxidation Plus Cathodic Electrophoretic Deposition on Magnesium Alloy

The composite coatings were prepared on AZ91D magnesium alloy by plasma electrolytic oxidation (PEO) plus cathodic electrophoretic deposition (E-coat) to improve corrosion protection. SEM observation revealed that the organic layer was integrated with PEO film by physically interlocking; Potentiodynamic polarization(E-i) measurements in 3.5% NaCl solution, copper accelerated acetate salt spray(CASS) test and immersion test were employed to evaluate corrosion principle and corrosion rate of composite coatings. It is indicated that the corrosion resistance of composite coatings was improved obviously compared to the PEO film. There is no noticeable pitting corrosion on the composite coatings after 320h CASS test. The adhesion of composite coatings was evaluated by cross-cut and pull-off test. The results show that adhesion of composite coatings can reach to level 0 and 11.3 N/mm2 as a result of the blocking effect between organic layer and PEO film.