Pure Mg samples were prepared by powder metallurgy using the cold and hot compacting methods. Cold compacted pure Mg (500 MPa/RT) was characterized by 5% porosity and the mechanical bonding of powder particles. Hot compacted samples (100 MPa/400 °C and 500 MPa/400 °C) exhibited porosity below 0.5%, and diffusion bonding combined with mechanical bonding played a role in material compaction. The prepared pure Mg samples and wrought pure Mg were subjected to corrosion tests using electrochemical impedance spectroscopy. Similar material corrosion behavior was observed for the samples compacted at 500 MPa/RT and 100 MPa/400 °C; however, hot compacted samples processed at 500 MPa/400 °C exhibited longer corrosion resistance in 0.9% NaCl solution. The difference in corrosion behavior was mainly related to the different binding mechanisms of the powder particles. Cold compacted samples were characterized by a more pronounced corrosion attack and the creation of a porous layer of corrosion products. Hot compacted samples prepared at 500 MPa/400 °C were characterized by uniform corrosion and the absence of a layer of corrosion products on the specimen surface. Powder-based cold compacted samples exhibited lower corrosion resistance compared to the wrought pure Mg, while the corrosion behavior of the hot compacted samples prepared at 500 MPa/400 °C was similar to that of wrought material.
Superhydrophobic surfaces were prepared using a two-step method that involved the etching of AZ31 and AZ91 magnesium alloys and then modifying the etched alloys with stearic acid. Magnesium alloys etched with ZnCl2 and SnCl2 exhibited surfaces roughened with micro- and nanoscale hierarchical structures consisting of two chemically distinct regions (Zn/Zn(OH)2 or Sn/SnO2 and Mg(OH)2). An optimum etching time of ten minutes was chosen for both etchants. Superhydrophobic surfaces with the highest contact angle were prepared when stearic acid reacted with the etched alloys at 50 °C for 4 h. Stearic acid was bound as zinc stearate and magnesium stearate on Mg alloys etched with ZnCl2 and SnCl2 solutions, respectively. The superhydrophobic process on AZ31 alloys etched with ZnCl2 and SnCl2 improved the corrosion resistance in phosphate buffered saline (PBS) solution compared to bare AZ31 alloy, with the use of ZnCl2 etchant leading to better results. An improvement in the corrosion resistance of AZ91 alloy was observed when the stearic-acid-modified AZ91 alloy was etched with SnCl2. In contrast, the use of ZnCl2 etchant to pretreat AZ91 alloy resulted in a significant deterioration in corrosion properties compared to bare AZ91 alloy. The microstructure of the Mg alloy had an impact on the etching and modification process. On the basis of the findings, a characterization of the chemistry of etching magnesium alloys and the formation of superhydrophobic surfaces was proposed. Magnesium alloys were prepared with superhydrophobic surfaces, incorporating antibacterial metals, features which may increase their potential for use in medical applications.
Plasma electrolytic oxidation (PEO) coatings with and without calcium phosphate (CaP) were prepared on AZ31 magnesium alloy including the CaP coating on AZ31 alloy. The microstructure of all coatings was characterized using an electron scanning microscope with energy dispersive spectroscopy (SEM/EDS). The PEO coating revealed the presence of many pores and microcracks on its surface. The deposition of CaP on the PEO layer led to the cover of these microstructural defects. Potentiodynamic polarization in 0.15 M NaCl medium showed that CaP/PEO, CaP and PEO coatings led to the improvement in the corrosion resistance when compared to bare AZ31 alloy. However, the corrosion resistance of CaP/PEO duplex coating was lower than PEO coating even though the CaP crystals covered the pores and microstructural defects.
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