Search Results (40)

A critical barrier to the clinical translation of biodegradable magnesium (Mg)-based materials lies in their rapid degradation rate in physiological environment, which leads to premature structural failure and compromised cytocompatibility. Micro-arc oxidation (MAO) coatings offer preliminary corrosion mitigation for Mg alloys, while their inherent structural porosity compromises long-term durability in physiological environment. To address this limitation, we developed a hierarchical coating system consisting of a dense Mg(OH)₂ interlayer (MAO/HT) superimposed on the MAO-treated substrate, followed by a functional polydopamine (PDA) topcoat to create a MAO/HT/PDA composite architecture. The surface characteristics and crystalline structures of these coatings were systematically characterized using field-emission scanning electron microscopy (FE-SEM), energy-dispersive X-ray spectroscopy (EDS), and X-ray diffraction (XRD). The corrosion resistance and interfacsial stability in physiological environment were quantitatively assessed through electrochemical analyses and long-term immersion tests in simulated body fluid (SBF). The cytocompatibility of the coatings was assessed by directly culturing osteoblast on the coated samples. The results reveal that the Mg(OH)₂ film possesses a bulk-like structure and effectively seals the micro-pores of the MAO coating. The current density of MAO/HT/PDA sample decreases by two orders of magnitude compared to that of MAO sample, indicating excellent corrosion resistance. The PDA layer not only acts as a strong barrier to improve the corrosion performance of the coating but also helps maintain the stability of the coating, thus delaying coating destruction in SBF. Moreover, the osteoblast culture results suggest that the MAO/HT/PDA coating promotes cell spread and proliferation noticeably compared to both the MAO and MAO/HT coatings. This study provides compelling evidence that the Mg(OH)₂/PDA composite coating is biodegradable and offers outstanding protection for micro-arc oxidized magnesium. As a result, it holds great promise for significant applications in the field of orthopedic medicine. Full article

The present study investigates the effect of different concentrations of Na₂WO₄ and graphene oxide dispersed composite additives on the structure and corrosion resistance of 6063 aluminum alloy micro-arc oxidation (MAO) coatings in a silicate electrolyte. The characterisation of the microstructure, cross-sectional morphology, elemental distribution, and phase composition of the films was conducted utilising scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), and X-ray diffraction (XRD). The corrosion resistance of the films was tested by prolonged immersion for 24 h, 72 h, 168 h, and 240 h, with measurement of kinetic potential polarisation curves and impedance modulus in a 3.5 wt.% NaCl solution. The densification of the films was enhanced with increasing mass concentration of Na₂WO₄ and dispersed graphene oxide in the electrolyte, and the thickness initially increased and then decreased. The film containing 6 g of Na₂WO₄ and 10 mL of graphene oxide dispersion (G10-6) exhibited optimal densification and thickness, with an I_corr value of 3.01 × 10⁻⁶ A·cm⁻² and a low-frequency impedance film value of 10⁸ Ω·cm², thereby demonstrating the most advanced corrosion resistance among the films. The densification and corrosion resistance of the films were enhanced by the incorporation of Na₂WO₄ and graphene oxide dispersion into the alkaline electrolyte. Full article

This study investigates the influence of micro-arc oxidation (MAO) duration on the formation and characteristics of ceramic coatings on 6061 aluminum alloys. MAO treatments were conducted in a silicate-based electrolyte for varying durations. The effects of oxidation time on film thickness, surface roughness, morphology, and phase composition were meticulously assessed using a film thickness gauge, surface roughness meter, scanning electron microscopy (SEM), and X-ray diffraction (XRD) analysis. The corrosion behavior of the coatings was evaluated in a 3.5% NaCl solution using an electrochemical workstation. The experimental results demonstrate that both the film thickness and surface roughness exhibit a positive correlation with oxidation time. Notably, the film growth rate initially increased before plateauing, suggesting an optimal oxidation duration. The coatings primarily comprise γ-Al₂O₃, α-Al₂O₃, and Al phases, with the proportions of γ-Al₂O₃ and α-Al₂O₃ increasing progressively with extended oxidation times. Comparative electrochemical tests revealed that the treated specimens exhibited significantly higher corrosion potential and reduced corrosion current densities compared to the untreated aluminum alloy substrate. Specifically, a coating produced with a 20 min oxidation time demonstrated an exceptional corrosion current density (J_corr) of 1.545 × 10⁻⁶ A·cm⁻² and a corrosion resistance (R_p) of 2.716 × 10⁴ Ω·cm², signifying the best corrosion resistance achieved in this study. These results underscore the pivotal role of oxidation time in tailoring the properties of micro-arc-oxidized layers on 6061 aluminum alloys, offering valuable insights for enhancing corrosion protection in practical applications. Full article

Metal oxide semiconductor (MOS) hydrogen sensors offer advantages, such as high sensitivity and fast response, but their challenges remain in achieving low-cost fabrication and stable operation at room temperature. This study investigates Nb-doped TiO₂ (NTO) thin films prepared via a one-step micro-arc oxidation (MAO) with the addition of Nb₂O₅ nanoparticles into the electrolyte for room-temperature hydrogen sensing. The characterization results revealed that the incorporation of Nb₂O₅ altered the film’s morphology and phase composition, increasing the Nb content and forming a homogeneous composite thin film. Hydrogen sensing tests demonstrated that the NTO samples exhibited significantly improved sensitivity, selectivity, and stability compared to undoped TiO₂. Among the fabricated samples, NTO thin film prepared at Nb₂O₅ concentration of 6 g/L (NTO-6) showed the best performance, with a broad detection range, excellent sensitivity, rapid response, and good specificity to hydrogen. A strong linear relationship between response values and hydrogen concentration (10–1000 ppm) highlights its potential for precise hydrogen detection. The enhanced hydrogen sensing mechanism of NTO thin films primarily stems from the influence of Nb₂O₅; nanoparticles doping in the anatase-phase TiO₂ structure on the semiconductor surface depletion layer, as well as the improved charge transfer and additional adsorption sites provided by the Nb/Ti composite metal oxides, such as TiNb₂O₇ and Ti_0.95Nb_0.95O₄. This study demonstrates the potential of MAO-fabricated Nb-doped TiO₂ thin films as efficient and reliable hydrogen sensors operating at room temperature, offering a pathway for novel gas-sensing technologies to support clean energy applications. Full article

Sodium tungstate (Na₂WO₄) was filled into the micropores and onto the surface of a magnesium alloy microarc oxidation (MAO) coating by means of vacuum impregnation. Subsequently, the coating was sealed through silane treatment to synergistically boost its corrosion resistance. The phase composition of the coating was inspected using XRD. FTIR was utilized to analyze the functional groups in the coating. XPS was employed to study the chemical composition and valence state of the coating. The surface and cross-sectional morphology of the coating, along with its elemental composition and distribution, were investigated by SEM and EDS. Meanwhile, the thickness of the coating was analyzed using Image J software. Electrochemical impedance spectroscopy (EIS) was employed to determine the corrosion resistance of the coating. The results show that compared with an MAO coating, M-0.125W composite coating (only filled with sodium tungstate on the surface of the MAO coating), and M-SG composite coating (only receiving silanization treatment applied to the surface of the MAO coating), the corrosion resistance of the M-nW-SG composite coating (loaded with sodium tungstate on the surface of the MAO coating and then treated with silane) is significantly improved. This is mainly attributed to the fact that sodium tungstate can be combined with Mg²⁺ to form insoluble magnesium tungstate protective film, which blocks corrosion media. At the same time, silanization treatment further seals the MAO coating and increases the compactness of the coating. In addition, with the increase in the impregnation concentration of sodium tungstate, the content of sodium tungstate in the M-nW-SG composite coating improves, and the sealing effect of silanization treatment is better. When the impregnation concentration of sodium tungstate is 0.1 mol/L or above, the MAO coating with sodium tungstate can be completely sealed. When the impregnation concentration of sodium tungstate is 0.125 mol/L, M-0.125W-SG composite coating has the best corrosion resistance, and its impedance modulus value can be maintained at 8.06 × 10⁶ Ω·cm² after soaking in 3.5 wt.% NaCl solution for 144 h, which is about three orders of magnitude higher than those of MAO coating and M-0.125W and M-SG composite coatings. Full article

The 7A04 Al alloy is a commonly used lightweight metal material; however, its low wear resistance limits its application. In this study, the wear resistance of this alloy was improved by preparing micro-arc oxidation (MAO) coatings, MAO/MoS₂ composite coatings, and hard-anodized (HA) coatings on its surface. The friction and wear behaviors of these three coatings with diamond-like coated (DLC) rings under oil lubrication conditions were investigated using a ring–block friction tester. The wear rates of the coatings on the block surfaces were determined using laser confocal microscopy, and the wear trajectories of the coatings were examined using scanning electron microscopy. The results indicated that, among the three coatings, the MAO/MoS₂ coating had the lowest coefficient of friction of 0.059, whereas the HA coating had the lowest wear rate of 1.47 × 10⁻⁶ mm/Nm. The MAO/MoS₂ coatings exhibited excellent antifriction properties compared to the other coatings, whereas the HA coatings exhibited excellent anti-wear properties. The porous structure of the MAO coatings stored lubricant and replenished the lubrication film under oil lubrication. Meanwhile, the introduced MoS₂ enhanced the densification of the coating and functioned as a solid lubricant. The HA coating exhibited good wear resistance owing to the dense structure of the amorphous-phase aluminum oxide. The mechanisms of abrasive and adhesive wear of the coatings under oil lubrication conditions and the optimization of the tribological properties by the solid–liquid synergistic lubrication effect were investigated. This study provides an effective method for the surface modification of Al alloys with potential applications in the aerospace and automotive industries. Full article

Micro-arc oxidation (MAO) films were fabricated on the Ti-39Nb-6Zr alloy at different voltages in the silicate and silicate/glycerin electrolyte. Their morphology, phase structure and composition were characterized by scanning electron microscopy (SEM) with energy dispersive X-ray spectroscopy (EDS), X-ray diffraction (XRD) and X-ray photoelectron spectroscopy (XPS). It was found that the glycerin additive in the silicate electrolyte improved the compactness of the MAO film. The corrosion resistance was evaluated, and the influence of glycerin additive in electrolyte on the growth of micro-arc oxidized film was revealed by optical emission spectra. Full article

In this study, we utilized Selective Laser Melting (SLM) technology to fabricate a magnesium alloy, and subsequently subject it to micro-arc oxidation treatment. We analyzed and compared the microstructure, elemental distribution, wetting angle, and corrosion resistance of the SLM magnesium alloy both before and after the micro-arc oxidation process. The findings indicate that the SLM magnesium alloy exhibits surface porosity defects ranging from 2% to 3.2%, which significantly influence the morphology and functionality of the resulting film layer formed during the micro-arc oxidation process. These defects manifest as pores on the surface, leading to an uneven distribution of micropores with varying sizes across the layer. The surface roughness of the 3D-printed magnesium alloy exhibits a high roughness value of 180 nanometers. The phosphorus (P) content is lower within the film layer compared to the surface, suggesting that the Mg₃(PO₄)₂ phase predominantly resides on the surface, whereas the interior is primarily composed of MgO. The micro-arc oxidation process enhances the hydrophilicity and corrosion resistance of the SLM magnesium alloy, thereby potentially endowing it with bioactivity. Additionally, the increased surface roughness post-treatment promotes cell proliferation. However, certain inherent defects present in the SLM magnesium alloy samples negatively impact the improvement of their corrosion resistance. Full article

Through a three-factor, two-level orthogonal experiment, the effects of varying electrical parameters (voltage, frequency, and duty cycle) on the thickness, pressure resistance, corrosion resistance, morphology, and phase composition of the micro-arc oxidized film of aluminum foil in constant voltage mode were investigated. The aluminum foil was oxidized by micro-arc oxidation for 50 min. Eddy-current thickness gauges were used to measure the oxide film’s thickness, TV characterization testers were used to test the film’s resistance to pressure, kinetic potential polarization curves were used to examine the oxide film’s resistance to electrochemical corrosion, and SEM and XRD composition were used to examine the microstructures and phase compositions of the oxide films that were produced. The oxide film’s thickness was increased from 7 μm to 22 μm and the voltage was increased from 350 V to 450 V. The oxide film’s ramp-up time at a frequency and duty cycle of 2000 Hz and 15% could reach 3 s, and the resistance value could reach 98% of the micro-arc oxidation voltage. The oxide film’s i_corr decreased by an order of magnitude at high voltage compared to low voltage and the R_p value increased by an order of magnitude, which improved the corrosion resistance. The oxide film’s thickness increased as the voltage increased. Meanwhile, SEM was used to enhance the corrosion resistance. The oxide film thickens as the voltage increases. At the same voltage, the oxide film with a high frequency and low duty cycle has the best voltage resistance. The oxide film generated under high-voltage conditions has regular and dense surface holes, the oxide film’s α-Al₂O₃ phase increases, and the corrosion resistance in the NaCl medium is enhanced. Full article

The surface corrosion of magnesium alloys is effectively addressed currently by the creation of a micro-arc oxidation (MAO) ceramic layer. However, oxide film porousness restricts magnesium alloy use. Thus, this work used atomic layer deposition (ALD) to create a TiO₂ coating on MAO-coated AZ31B magnesium alloy to plug micropores and increase corrosion resistance and biological characteristics. The samples were analyzed using SEM, EDS, XPS, and XRD to determine their surface appearance, chemical content, and microstructure. Micro-arc oxidation produced a 20 μm oxide coating. The TiO₂ film reached 47.41 nm after 400 atomic layer deposition cycles. All corroded samples were tested for corrosion resistance using electrochemical and hydrogen evolution methods and examined for surface morphology. In vitro cell experiments examined biocompatibility. The results indicate that the TiO₂ layer sealed the MAO coating’s micro-pores and micro-cracks, enhanced corrosion resistance, and preserved surface morphology following corrosion. The TiO₂/MAO composite coating is more biocompatible than the substrate and MAO coating. This research proposes coating AZ31B magnesium alloy for bio-remediation to increase corrosion resistance and biocompatibility. Full article

The presence of inherent micro-pores and micro-cracks in the micro-arc oxidation (MAO) film of Mg alloys is a key factor contributing to substrate corrosion. A composite film layer with high corrosion resistance was achieved through silanizing the micro-arc oxidation film. The corrosion performance of the MAO films treated with various silane coupling agents was assessed through morphological characterization and electrochemical tests. SEM graphs depicted that the silane film can effectively seal the defects existing in micro-arc oxidation film, and electrochemical tests indicated the significant corrosion resistance improvement of MAO film after silanization treatment. Full article

Micro-arc oxidation (MAO) is a promising technology for enhancing the wear resistance of engine cylinders by growing a high hardness alumina ceramic film on the surface of light aluminum engine cylinders. However, the positive and negative pulse coordination, voltage characteristic signal, hardness distribution characteristics of the ceramic film, and their internal mechanism during the growth process are still unclear. This paper investigates the synergistic effect mechanism of cathodic and anodic current on the growth behaviour of alumina, dynamic voltage signal, and hardness distribution of micro-arc oxidation film. Ceramic film samples were fabricated under various conditions, including current densities of 10, 12, 14, and 16 A/dm², and current density ratios of cathode and anode of 1.1, 1.2, and 1.3, respectively. Based on the observed characteristics of the process voltage curve and the spark signal changes, the growth of the ceramic film can be divided into five stages. The influence of positive and negative current density parameters on the segmented growth process of the ceramic film is mainly reflected in the transition time, voltage variation rate, and the voltage value of different growth stages. Enhancing the cathode pulse effect or increasing the current density level can effectively shorten the transition time and accelerate the voltage drop rate. The microhardness of the ceramic film cross-section presents a discontinuous soft-hard-soft regional distribution. Multiple thermal cycles lead to a gradient differentiation of the Al₂O₃ crystal phase transition ratio along the thickness direction of the layer. The layer grown on the outer surface of the initial substrate exhibits the highest hardness, with a small gradient change in hardness, forming a high hardness zone approximately 20–30 μm wide. This high hardness zone extends to both sides, with hardness decreasing rapidly. Full article

Cr coatings with a thickness of about 19 μm were synthesized on Zr-4 cladding using plasma-enhanced arc ion plating. A Zr-Cr micro-diffusion layer was formed via Cr ion cleaning before deposition to enhance the interface bonding strength. Cr coatings exhibit an obvious columnar crystal structure with an average grain size of 1.26 μm using SEM (scanning electron microscopy) and EBSD (electron backscatter diffraction) with a small amount of nanoscale pores on the surface. A long-term aqueous test at 420 ± 3 °C, 10.3 ± 0.7 MPa and isothermal oxidation tests at 900~1300 °C in air were conducted to evaluate the Cr-coated Zr-4 cladding. All the results showed that the Cr coatings had a significant protective effect to the Zr-4 alloy. However, the corrosion deterioration mechanism is different. A gradual thinning of the Cr coating was observed in a long-term aqueous test, but a cyclic corrosion mechanism of void initiation–propagation–cracking at the oxide film interface is the main corrosion characteristic of the Cr coating in isothermal oxidation. Different corrosion models are constructed to explain the corrosion mechanism. Full article

Aluminum alloys are widely used in a variety of industries nowadays for their high strength-to-weight ratio, good formability, low density, and recyclability. However, their poor corrosion and wear resistance properties restrict their applications. This study investigated the effects of electrical parameters and electrolyte compositions on the microstructures of micro-arc oxidation (MAO) film on a 7075 Al alloy substrate. The morphology, microstructure, and compositions of the MAO coatings were characterized using a scanning electron microscope (SEM), X-ray diffraction (XRD), and an electron probe micro-analyzer (EPMA). Furthermore, measurements of microhardness, corrosion resistance, and wear resistance were also conducted. The cathodic current and duty ratio are proportional to film thickness, which consequently improves the wear and corrosion resistance. The microstructural observations of the aluminate-based coatings revealed that increasing cathodic current reduces the pancake-like structures, and a lot of small pores appear on the top of the coatings, which makes the surface smoother. Moreover, the aluminate-based coatings are mainly composed of α-Al₂O₃ and γ-Al₂O₃, while the silicate-based coatings mainly consist of γ-Al₂O₃ and a small amount of α-Al₂O₃ phase. Due to the phase compositions, the microhardness of the aluminate-based coatings can reach 1300~1500 HV and exhibit better wear resistance than silicate-based coatings. Full article

Aluminum (Al) alloys are lightweight and machinable and have been widely used in industrial applications, particularly the formation of complex mechanical parts. However, the 5052 Al alloy frequently encounters problems like corrosion and wear during its service life, significantly impacting the equipment’s longevity. This study investigated the effects of pulse voltage (320 to 400 V) and frequency (50 to 200 Hz) on the growth and surface morphology of 5052 Al alloy films formed through micro-arc oxidation (MAO) to improve their corrosion and wear resistance while maintaining a surface roughness of less than 1 μm. The results indicate that higher operating voltages and frequencies correlated with increased thickness in the resulting ceramic oxide films formed using MAO. In addition, as the pulse frequency increased, the distribution of the holes became more uniform across the surface. We examined the surface and cross-sectional morphology, as well as the thickness of the MAO coatings, through scanning electron microscopy (SEM). The corrosion and wear resistance of the MAO coatings formed under different electrical parameters were analyzed using electrochemical corrosion tests and scratch tests. The MAO coatings produced at 400 V and 200 Hz were the thickest, at approximately 4.8 μm, and demonstrated superior corrosion and wear resistance. These coatings demonstrate significantly reduced wear width, highlighting their exceptional resistance to corrosion and wear. Hole cracking occurred only above the top layer of the coating and not beneath the mid-layer, which protected the substrate from damage due to the direct passage of Cl ions through the holes. Full article