Influence of microstructure and composition on the corrosion behaviour of Mg/Al alloys in chloride media

Ion-bombardment-driven surface modification of porous magnesium scaffolds: Enhancing biocompatibility and osteoimmunomodulation

Porous Mg scaffolds are promising for bone repair but are limited by high corrosion rates and challenges in preserving coating integrity. We used Directed Plasma Nanosynthesis (DPNS) at 400 eV and a fluence of 1 × 1018 cm-2 to augment the bioactivity and corrosion resistance of porous Mg scaffolds, maintaining their overall material integrity. DPNS creates nanostructures that increase surface area, promote apatite nucleation, and enhance osseointegration, improving the bioactivity and corrosion resistance of porous Mg scaffolds without compromising their structure. Our findings indicate a decrease in surface roughness, with pre-irradiated samples having Rq = 60.4 ± 5.3 nm andRa = 48.2 ± 3.1 nm, and post-DPNS samples showing Rq = 36.9 ± 0.3 nm andRa = 28.6 ± 0.8 nm. This suggests changes in topography and wettability, corroborated by the increased water contact angles (CA) of 129.2 ± 3.2 degrees. The complexity of the solution influences the CA: DMEM results in a CA of 120.4 ± 0.1 degrees, while DMEM + SBF decreases it to 103.6 ± 0.5 degrees, in contrast to the complete spreading observed in non-irradiated samples. DPNS-treated scaffolds exhibit significantly reduced corrosion rates at 5.7 × 10-3 ± 3.8 × 10-4 mg/cm²/day, compared to the control's 2.3 × 10-2 ± 3.2 × 10-4 mg/cm²/day over 14 days (P < 0.01). The treatment encourages the formation of a Ca-phosphate-rich phase, which facilitates cell spreading and the development of focal adhesion points in hBM-MSCs on the scaffolds. Additionally, J774A.1 murine macrophages show an enhanced immune response with diminished TNF-α cytokine expression. These results offer insights into nanoscale modifications of Mg-based biomaterials and their promise for bone substitutes or tissue engineering scaffolds.

The Effect of Mechanical Pretreatment on the Electrochemical Characteristics of PEO Coatings Prepared on Magnesium Alloy AZ80

The main objective of this article is to provide new information on the effects of mechanical pretreatment of AZ80 magnesium alloy ground with SiC emery papers of different grain sizes on the plasma electrolytic oxidation (PEO) process and corrosion properties of AZ80 in 0.1 M NaCl solution. Then, the roughness of the coated samples was measured by confocal microscopy. The corrosion properties of the ground and coated surfaces were determined by potentiodynamic polarization (PDP) within 1 h of exposure, and electrochemical impedance spectroscopy (EIS) was performed during 168 h of exposure at laboratory temperature. Consequently, the obtained results of the PDP measurements were evaluated by the Tafel analysis and the EIS evaluation was performed by the equivalent circuit analysis through Nyquist diagrams. The morphology and structure of PEO coatings were observed by scanning electron microscopy (SEM) through the secondary imaging technology, and the presence of certain elements in PEO coatings was analyzed by EDS analysis.

Progress of laser surface treatment on magnesium alloy

Magnesium (Mg) metals have been widely used in various fields as one of the most promising lightweight structural materials. However, the low corrosion resistance and poor mechanical properties restrict its applications. Surface treatments are common approach to enhance the mechanical strength and corrosion resistance of Mg metals. Among them, laser surface treatment generates novel tissues and structures in situ on the sample surface, thereby improving properties of mechanical strength and corrosion resistance. We briefly describe the changes in surface organization that arise after laser treatment of Mg surfaces, as well as the creation of structures such as streaks, particles, holes, craters, etc., and provide an overview of the reasons for the alterations. The effect of laser processing on wettability, hardness, friction wear, degradation, biocompatibility and mechanical properties were reviewed. At last, the limitations and development trend of laser treatment on Mg metals research were further pointed out.

Understanding the Corrosion Behavior of the AZ91D Alloy in Simulated Body Fluid through the Use of Dynamic EIS

Dynamic electrochemical impedance spectroscopy (dynamic EIS) has the capacity to track changes on surfaces in a changing corrosive system, an advantage it holds over classical EIS. We used the dynamic EIS approach to provide insight into the corrosion behavior of the AZ91D Mg alloy in simulated body fluid for 30 h at 25 °C. The results reveal that the impedance response of the alloy is influenced by the immersion time. Between 0 and 7 h, impedance with three time constants was obtained, whereas two-time-constant impedance spectra were obtained between 8 and 30 h of immersion. The results confirm the breakdown of the corrosion product at longer immersion times.

Evolution of Microstructure and Mechanical Properties of Mg-6Al Alloy Processed by Differential Speed Rolling upon Post-Annealing Treatment

Magnesium-6 wt.% aluminum (Mg-6Al) alloy plates with a 6-millimeter thickness were processed from an initial 12-millimeter thickness by differential speed rolling (DSR), with a 0.76-millimeter thickness reduction per pass using a speed ratio of 2, preheating temperature of 315 °C, and roll temperature of 265 °C. The effects of annealing temperature of 250, 275, and 300 °C with a corresponding holding time of 15 min on the microstructure, texture, and mechanical properties were investigated. Key results show that dynamic recrystallization (DRX) occurred during the roll processing, resulting in a greatly reduced grain size. In addition, the basal pole of the as-rolled plate was inclined to the rolling direction (RD) by ~20°, due to the shear strain introduced during DSR. Subsequent annealing caused grain growth, eliminated the basal pole inclination towards the RD, and slightly increased the pole intensity. Compared with the as-rolled plate, the average of the ultimate tensile strength (UTS) and the yield strength (YS) of the annealed plates decreased, while the average elongation at fracture (εf) increased. With the annealing temperature of 275 °C, the plate achieved a good combination of mechanical properties with UTS, YS, and εf being 292.1 MPa, 185.0 MPa, and 24.9%, respectively. These results suggest that post-roll annealing is an effective way to improve the mechanical response of this Mg alloy processed by DSR.

Experimental Apparent Stern–Geary Coefficients for AZ31B Mg Alloy in Physiological Body Fluids for Accurate Corrosion Rate Determination

The corrosion behavior of AZ31B Mg alloy exposed to Ringer’s, phosphate-buffered saline (PBS), Hank’s, and simulated body fluid (SBF) solutions for 4 days was investigated using electrochemical impedance spectroscopy (EIS), potentiodynamic polarization, weight loss, and surface characterization. Changes in corrosion rates with immersion time determined by weight loss measurements were compared with EIS data to determine the possibility of obtaining quantitative electrochemical information. In addition, changes in the protective properties of the corrosion product layer calculated from the EIS parameters were evaluated as a function of their surface chemical composition as determined by X-ray photoelectron spectroscopy (XPS) and visual observations of the corroded specimen’s surface. Apparent Stern–Geary coefficients for the AZ31B Mg alloy in each test solution were calculated using the relationship between icorr from weight loss measurements and the EIS data (both Rp and Rt). This provided experimental reference B′ values that may be used as a useful tool in independent investigations to improve the accuracy of corrosion rates of AZ31B Mg alloy in simulated body solutions.

Organic/inorganic double solutions for magnesium–air batteries

In order to limit the anode corrosion and improve the battery activity, magnesium–air batteries with organic/inorganic double solutions (0.5 M Mg(ClO₄)₂–N,N-dimethylformamide (DMF)/0.6 M NaCl–H₂O, 0.5 M Mg(ClO₄)₂–acetonitrile (AN)/0.6 M NaCl–H₂O) were prepared.

Corrosion behavior of an AZ91D magnesium alloy under a heterogeneous electrolyte layer

The corrosion behavior of an AZ91D magnesium alloy was investigated under a heterogeneous electrolyte layer by using electrochemical methods and surface analysis techniques. Dynamic polarization curves and morphological characterization were obtained at the center and near the edge zones under the electrolyte layer. The influence of the gas/liquid/solid three-phase boundary zone (TPB) on the corrosion behavior of the AZ91D magnesium alloy was discussed. The corrosion rate changed more significantly near the TPB zone than that at the other zones. The AZ91D alloy exhibited the characteristics of filiform corrosion together with shallow pitting corrosion. Different from the randomly distributed shallow pits, the filiform corrosion preferred to initiate near the TPB region and then progressively expanded adjacent to the edge of the electrolyte layer. The TPB zone played a vital role in determining the corrosion location, the corrosion morphologies and the corrosion rate of the magnesium alloy by influencing the mass transport process of carbon dioxide.

Electrochemical Impedance Spectroscopy for the Measurement of the Corrosion Rate of Magnesium Alloys: Brief Review and Challenges

From a technological point of view, measurement of the corrosion rate of magnesium (Mg) and its alloys is critical for lifetime predictions of Mg-based structures and for comparative assessments of their corrosion protection ability. Whilst weight loss, hydrogen evolution, and polarization curves methods are frequently used for measuring the corrosion rate, the determination of values by electrochemical impedance spectroscopy (EIS) is relatively scarce and has only been realized recently. This technique seems to be the most suitable for monitoring corrosion rate values due to its “non-destructive” character, its reproducibility, and its reliable determination of small corrosion rates, much lower than those measured by other techniques. This review aims to picture the state-of-the-art technique of using EIS for measuring the corrosion rate of Mg. This paper starts by introducing some fundamental aspects of the most widely used methods for monitoring the corrosion rate of Mg/Mg alloy and continues by briefly explaining some of the fundamental concepts surrounding EIS, which are essential for the user to be able to understand how to interpret the EIS spectra. Lastly, these concepts are applied, and different approaches that have been proposed to obtain quantitative values of corrosion rate since the 1990s are discussed.

De-alloying Behavior of Mg-Al alloy in Sulphuric Acid and Acetic Acid Aqueous Solutions

The fabricated Mg–Al alloy consists of α-Mg phase and Mg–Mg₁₇Al₁₂ eutectic phase. The corrosion behavior of cast Mg–Al alloy in sulphuric acid (H₂SO₄) and acetic acid (HAc) aqueous solutions was investigated. The Mg–Al alloy shows general corrosion in H₂SO₄ solution, and the α-Mg dendrites revealed a slightly faster corrosion rate than that of the eutectics. In HAc solution, the alloy shows an obvious selective corrosion characteristic, with the α-Mg dendrites being corroded preferentially. Grain orientation plays an important role in corrosion behavior of the alloy in the HAc solutions.

Degradation Behaviour of Mg0.6Ca and Mg0.6Ca2Ag Alloys with Bioactive Plasma Electrolytic Oxidation Coatings

Bioactive Plasma Electrolytic Oxidation (PEO) coatings enriched in Ca, P and F were developed on Mg0.6Ca and Mg0.6Ca2Ag alloys with the aim to impede their fast degradation rate. Different characterization techniques (SEM, TEM, EDX, SKPFM, XRD) were used to analyze the surface characteristics and chemical composition of the bulk and/or coated materials. The corrosion behaviour was evaluated using hydrogen evolution measurements in Simulated Body Fluid (SBF) at 37 °C for up to 60 days of immersion. PEO-coated Mg0.6Ca showed a 2–3-fold improved corrosion resistance compared with the bulk alloy, which was more relevant to the initial 4 weeks of the degradation process. In the case of the Mg0.6Ag2Ag alloy, the obtained corrosion rates were very high for both non-coated and PEO-coated specimens, which would compromise their application as resorbable implants. The amount of F− ions released from PEO-coated Mg0.6Ca during 24 h of immersion in 0.9% NaCl was also measured due to the importance of F− in antibacterial processes, yielding 33.7 μg/cm2, which is well within the daily recommended limit of F− consumption.

Effect of Al Content in the Mg-Based Alloys on the Composition and Corrosion Resistance of Composite Hydroxide Films Formed by Steam Coating

Mg alloys are expected to be used in fields of the transportation industry because of their lightweight property, however, they show low corrosion resistance. To improve the corrosion resistance, preparation of the protective film on Mg alloys is essential. In this study, composite hydroxide films were prepared on three types of Mg alloys with different aluminum contents—that is, AZ31, AZ61, and AZ91D—by steam coating to investigate the relationship between the Mg-Al layered double hydroxide (LDH) content in the film and the Al content in the Mg alloys. Scanning electron microscopy (SEM) observation demonstrated that films were formed densely on all Mg alloy surfaces. X-ray diffraction (XRD) analyses revealed that all films prepared on AZ61 and AZ91D were composed of Mg(OH)₂, AlOOH, and Mg-Al LDH, while the film containing Mg(OH)₂ and Mg-Al LDH were formed only on AZ31. The Mg-Al LDH content in the film prepared on AZ61 was relatively higher than those prepared on AZ31 and AZ91D. The content of AlOOH in the film increased with an increase in the Al content in the Mg alloys. The film thickness changed depending on the treatment time and type of Mg alloy. Polarization curve measurements in 5 mass% NaCl solution demonstrated that the film prepared on the AZ61 showed complete passive behavior within the potential range of −1.0 to −0.64 V. In addition, immersion tests in 5 mass% NaCl aqueous solution for 480 h demonstrated that the film on the AZ61 had superior durability against 5 mass% NaCl aqueous solution. These results indicated that the film on the AZ61 had the most superior corrosion resistance among all samples. The results obtained in this study suggest that the LDH content in the film could be related to the corrosion resistance of the film.

Optimization of AZ91D Process and Corrosion Resistance Using Wire Arc Additive Manufacturing

Progress on Additive Manufacturing (AM) techniques focusing on ceramics and polymers evolves, as metals continue to be a challenging material to manipulate when fabricating products. Current methods, such as Selective Laser Sintering (SLS) and Electron Beam Melting (EBM), face many intrinsic limitations due to the nature of their processes. Material selection, elevated cost, and low deposition rates are some of the barriers to consider when one of these methods is to be used for the fabrication of engineering products. The research presented demonstrates the use of a Wire and Arc Additive Manufacturing (WAAM) system for the creation of metallic specimens. This project explored the feasibility of fabricating elements made from magnesium alloys with the potential to be used in biomedical applications. It is known that the elastic modulus of magnesium closely approximates that of natural bone than other metals. Thus, stress shielding phenomena can be reduced. Furthermore, the decomposition of magnesium shows no harm inside the human body since it is an essential element in the body and its decomposition products can be easily excreted through the urine. By alloying magnesium with aluminum and zinc, or rare earths such as yttrium, neodymium, cerium, and dysprosium, the structural integrity of specimens inside the human body can be assured. However, the in vivo corrosion rates of these products can be accelerated by the presence of impurities, voids, or segregation created during the manufacturing process. Fast corrosion rates would produce improper healing, which, in turn, involve subsequent surgical intervention. However, in this study, it has been proven that magnesium alloy AZ91D produced by WAAM has higher corrosion resistance than the cast AZ91D. Due to its structure, which has porosity or cracking only at the surface of the individual printed lines, the central sections present a void-less structure composed by an HCP magnesium matrix and a high density of well dispersed aluminum-zinc rich precipitates. Also, specimens created under different conditions have been analyzed in the macroscale and microscale to determine the parameters that yield the best visual and microstructural results.

The Corrosion Behavior of AZ91D Magnesium Alloy in Simulated Haze Aqueous Solution

The corrosion process of AZ91D magnesium alloy in simulated haze aqueous solution has been studied by electrochemical measurements, immersion tests and morphology characterization. Results show that AZ91D was corroded heavily in simulated haze aqueous solution due to the loose and breakable product film on the surface providing little corrosion barrier. The effect of different ions was investigated. It was found that both NO3− and NH4+ played an important role in the corrosion process. NO3− helped to form passive film to protect the matrix, yet NH4+ consumed OH⁻, resulting in the absence of Mg(OH)₂ and serious corrosion. Meanwhile, SO42− and Cl⁻ had influence on pitting corrosion. Magnesium aluminum oxide and MgAl₂(SO₄)₄·22H₂O instead of Mg(OH)₂ were the dominate products, which is different from the former study. Corrosion rate changed with time, especially in the first 3 h. A two-stage corrosion mechanism is proposed after considering both the corrosion process and the influence of ions.

Different graphene layers to enhance or prevent corrosion of polycrystalline copper

Graphene was used as an anticorrosive coating for metals as it can effectively isolate the corrosion factors such as oxygen. However, we found that the anticorrosive and corrosive effects on metal surface were related to graphene layers and metal crystal faces. In this paper, we found that different layers of graphene had significantly different effects on the corrosion of polycrystalline copper during long-term storage under atmospheric conditions. Optical images and Raman spectra showed that single layer graphene (SLG)-coated copper had a higher degree of corrosion than bare copper. However, when covered with CVD in situ-grown bilayer graphene (BLG), the copper foil was effectively prevented from being etched as it exhibited a bright yellow color despite the differences in crystal faces. The surface potential differences measured by an electric force microscope (EFM) showed that a contact potential difference (V_CPD) between 30 and 40 mV existed between Cu/SLG and bare copper. The SLG-coated areas had a higher surface potential (SP), which meant that the (SLG)-coated copper was more prone to lose electrons to exhibit galvanic corrosion. The BLG coating made SP of underlying copper lower making it harder to lose electrons; thus, BLG successfully protected the copper from being corroded. These findings have a foreseeable significance for graphene as a metal anti-corrosion coating.

The degree of corrosion depends on the crystal faces and number of graphene layers, whereas BLG can be used as an anticorrosion coating.

The effects of NaF concentration on electrochemical and corrosion behavior of AZ31B magnesium alloy in a composite electrolyte

Electrochemical and corrosion behavior of AZ31B magnesium alloy have been investigated in composite solution of MgSO₄–Mg(NO₃)₂ (0.14 mol L⁻¹ MgSO₄, 1.86 mol L⁻¹ Mg(NO₃)₂) under different sodium fluoride (NaF) concentrations.

Influence of Surrounding Cations on the Surface Degradation of Magnesium Alloy Implants under a Compressive Pressure

The effect of cations in the surrounding solutions on the surface degradation of magnesium alloys, a well-recognized biodegradable biomaterial, has been neglected compared with the effect of anions in the past. To better simulate the compressive environment where magnesium alloys are implanted into the body as a cardiovascular stent, a device is designed and employed in the test so that a pressure, equivalent to the vascular pressure, can be directly applied to the magnesium alloy implants when the alloys are immersed in a medium containing one of the cations (K(+), Na(+), Ca(2+), and Mg(2+)) found in blood plasma. The surface degradation behaviors of the magnesium alloys in the immersion test are then investigated using hydrogen evolution, mass loss determination, electron microscopy, pH value, and potentiodynamic measurements. The cations are found to promote the surface degradation of the magnesium alloys with the degree decreased in the order of K(+) > Na(+) > Ca(2+) > Mg(2+). The possible mechanism of the effects of the cations on the surface degradation is also discussed. This study will allow us to predict the surface degradation of magnesium alloys in the physiological environment and to promote the further development of magnesium alloys as biodegradable biomaterials.

Effect of biologically relevant ions on the corrosion products formed on alloy AZ31B: an improved understanding of magnesium corrosion

Simulated physiological solutions mimicking human plasma have been utilized to study the in vitro corrosion of biodegradable metals. However, corrosion and corrosion product formation are different for different solutions with varied responses and, hence, the prediction of in vivo degradation behavior is not feasible based on these studies alone. This paper reports the role of physiologically relevant salts and their concentrations on the corrosion behavior of a magnesium alloy (AZ31B) and subsequent corrosion production formation. Immersion tests were performed for three different concentrations of Ca(2+), HPO4(2-), HCO3(-) to identify the effect of each ion on the corrosion of AZ31B assessed at 1, 3 and 10 days. Time-lapse morphological characterization of the samples was performed using X-ray computed tomography and scanning electron microscopy. The chemical composition of the surface corrosion products was determined by electron dispersive X-ray spectroscopy and X-ray diffraction. The results show that: (1) calcium is not present in the corrosion product layer when only Cl(-) and OH(-) anions are available; (2) the presence of phosphate induces formation of a densely packed amorphous magnesium phosphate corrosion product layer when HPO4(2-) and Cl(-) are present in solution; (3) octacalcium phosphate and hydroxyapatite (HAp) are deposited on the surface of the magnesium alloy when HPO4(2-) and Ca(2+) are present together in NaCl solution (this coating limits localized corrosion and increases general corrosion resistance); (4) addition of HCO3(-) accelerates the overall corrosion rate, which increases with increasing bicarbonate concentration; (5) the corrosion rate decreases due to the formation of insoluble HAp on the surface when HCO3(-), Ca(2+), and HPO4(2-) are present together.

Experimental data confirm numerical modeling of the degradation process of magnesium alloys stents

Biodegradable magnesium alloy stents (MAS) could present improved long-term clinical performances over commercial bare metal or drug-eluting stents. However, MAS were found to show limited mechanical support for diseased vessels due to fast degradation. Optimizing stent design through finite element analysis (FEA) is an efficient way to improve such properties. Following previous FEA works on design optimization and degradation modeling of MAS, this work carried out an experimental validation for the developed FEA model, thus proving its practical applicability of simulating MAS degradation. Twelve stent samples of AZ31B were manufactured according to two MAS designs (an optimized one and a conventional one), with six samples of each design. All the samples were balloon expanded and subsequently immersed in D-Hanks' solution for a degradation test lasting 14 days. The experimental results showed that the samples of the optimized design had better corrosion resistance than those of the conventional design. Furthermore, the degradation process of the samples was dominated by uniform and stress corrosion. With the good match between the simulation and the experimental results, the work shows that the FEA numerical modeling constitutes an effective tool for design and thus the improvement of novel biodegradable MAS.