Magnesium alloys have received a great amount of attention regarding being used in biomedical applications; however, they show high degradability, poor bioactivity, and biocompatibility. To improve these properties, surface modification and various types of coatings have been applied. In this study, an anodized AZ91 alloy was coated with a polymer matrix composite made of polycaprolactone/chitosan (PCL/Ch) with different percentages of baghdadite to improve its resistance to corrosion, bioactivity, and biocompatibility. The effects of different percentages of baghdadite (0 wt %, 1 wt %, 3 wt %, and 5 wt %) on the surface microstructure, corrosion resistance, roughness, and wettability were evaluated. The results indicated that the applied nano-polymer-ceramic coating including 3 wt % baghdadite was hydrophobic, which consequently increased the corrosion resistance and decreased the corrosion current density of the anodized AZ91 alloy. Coating with 3 wt % baghdadite increased the roughness of AZ91 from 0.329 ± 0.02 to 7.026 ± 0.31 μm. After applying the polymer-ceramic coating on the surface of anodized AZ91, the corrosion products changed into calcium–phosphate compounds instead of Mg(OH)2, which is more stable in a physiological environment.

Polymer-ceramic composite coatings on magnesium-based alloys have attracted lots of attention in recent years, to control the speed of degradability and to enhance bioactivity and biocompatibility. In this study, to decrease the corrosion rate in a simulated body fluid (SBF) solution for long periods, to control degradability, and to enhance bioactivity, polycaprolactone-chitosan composite coatings with different percentages of baghdadite (0 wt.%, 3 wt.%, and 5 wt.%) were applied to an anodized AZ91 alloy. According to the results of the immersion test of the composite coating containing 3 wt.% baghdadite in a phosphate buffer solution (PBS), the corrosion rate decreased from 0.45 (for the AZ91 sample) to 0.11 mg/cm 2 ·h after seven days of immersion. To evaluate the apatite formation capability of specimens, samples were immersed in an SBF solution. The results showed that the samples were bioactive as apatite layers formed on the surface of specimens. The composite coating containing 3 wt.% baghdadite showed the highest apatite-formation capability, with a controlled release of ions, and the lowest corrosion rate in the SBF.