Composite Ceramic Layer via Friction Stir Welding and Micro-Arc Oxidation on Nickel–Aluminum Bronze: Microstructure and Erosion–Corrosion Resistance

Nickel–aluminum bronze (NAB) propellers can be severely damaged by the synergistic action of chloride corrosion and solid–liquid erosion in marine environments. However, the direct application of micro-arc oxidation (MAO) to NAB is fundamentally hindered because NAB is a non-valve metal. Herein, this limitation is circumvented via a novel hybrid strategy integrating friction stir welding (FSW) and MAO. A defect-free aluminum transition layer is first fabricated onto NAB by FSW and thinned to ~30 μm for MAO. An Al₂O₃-based composite ceramic coating is synthesized, exhibiting a duplex structure with α/γ-Al₂O₃ and an amorphous Si-O network. The coating demonstrates a nano-hardness of 16.2 ± 2.0 GPa and an elastic modulus of 251.3 ± 31.1 GPa, underpinned by a robust interfacial tensile strength of 72.7 MPa. In 3.5 wt.% NaCl, the corrosion current density is suppressed to 1.335 ± 0.151 × 10⁻⁷ A/cm², while the charge transfer resistance reaches 3.072 × 10⁵ Ω·cm². Mass loss after 30-day immersion is reduced to ~1/11 of NAB, and erosion loss at 400 rpm is ~1/8 of that of the substrate. Electrochemical results indicate that the Al transition layer provides an initial beneficial contribution, while the MAO ceramic coating further delivers the dominant barrier protection, together leading to the best overall corrosion resistance of the hybrid-treated sample.