NaF assisted preparation and the improved corrosion resistance of high content ZnO doped plasma electrolytic oxidation coating on AZ31B alloy

In the present research, the NaF assisted plasma electrolytic oxidation (PEO) is designed to fabricate the high-content ZnO nanoparticles doped coating on AZ31B alloy. The microstructure, phase constituents and corrosion behavior of the PEO coatings are investigated systematically. The results reveal that the introduction of NaF promotes the formation of MgF2 nanophases in the passivation layer on Mg alloy, decreasing the breakdown voltage and discharge voltage. As a result, the continuous arcing caused by high discharge voltage is alleviated. With the increasing of NaF content, the Zn content in the PEO coating is enhanced and the pore size in the coating is decreased correspondingly. Due to the high-content ZnO doping, the PEO coating protected AZ31B alloy demonstrates the better corrosion resistance. Compared with the bare AZ31B alloy, the high-content ZnO doped PEO coated sample shows an increased corrosion potential from -1.465 V to -1.008 V, a decreased corrosion current density from 3.043×10-5 A·cm-2 to 3.960×10-8 A·cm-2 and an increased charge transfer resistance from 1.213×102 ohm·cm2 to 2.598×105 ohm·cm2. Besides, the high-content ZnO doped PEO coated sample also has the excellent corrosion resistance in salt solution, exhibiting no obvious corrosion after more than 2000 h neutral salt spraying and 28 days’ immersion testing. The improved corrosion resistance can be ascribed to the relative uniform distribution of ZnO in PEO coating which can transform to Zn(OH)2 and form a continuous protective layer along the corrosion interface.