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Purpose: The impact of rolling on the performance of micro arc oxidation (MAO) coatings on ZM5 alloy has been underreported. The purpose of this study is to explore the correlation between rolling and the failure mechanism of MAO coatings in greater depth. Design/methodology/approach: The influence of rolling on the corrosion and wear properties of MAO coating was investigated by phase structure, bond strength test (initial bond strength and wet adhesion), electrochemical impedance spectroscopy and wear test. The change of the surface electrochemical properties was studied by first principles analysis. Findings: The results showed that the MAO coating on rolled alloy had better corrosion and wear resistance compared to cast alloy, although the structure and component content of two kinds of MAO coating are nearly identical. The difference in interface bonding between MAO coating and Mg substrate is the primary factor contributing to the disparity in performance between the two types of samples. Finally, the impact of the rolling process on MAO coating properties is explained through first-principle calculation. Originality/value: A comprehensive explanation of the impact of the rolling process on MAO coating properties will provide substantial support for enhancing the application of Mg alloy anticorrosion. [ABSTRACT FROM AUTHOR]

MAO coating is a significant research topic to improve the corrosion resistance of Mg alloys, which are currently being received much attention. The majority of current research is centered on optimizing the pore structure of MAO coatings to improve corrosion resistance, but the bonding between the coating and the substrate has been neglected. In this work, MAO coatings with different porosity and adhesion strength were obtained in phosphate and silicate electrolytes at different voltages. The structure, chemical composition, and mechanical properties of MAO coatings were also analyzed by various means, and their corrosion resistance was tested by electrochemical metholds. The influence of porosity and adhesion on the corrosion resistance of the coatings was analyzed and their mechanism has been examined, which is beneficial to obtain longer corrosion resistance MAO coating. [Display omitted] • The corrosion failure progress and mechanism of MAO coating prepared in different electrolytes has been studied. • The key factors affecting the corrosion resistance of microarc oxidation coating has been studied. • Enhanced adhesion strength can improve the corrosion resistance of MAO coatings. [ABSTRACT FROM AUTHOR]

• The corrosion failure progress and mechanism of MAO coating has been studied. • The surface roughness affects the bonding strength of the MAO coating significantly. • The high surface roughness could dramatically improve the corrosion resistance of MAO coating. In this study, micro-arc oxidation (MAO) coatings were formed on ZM5 Mg alloy substrate with different surfaces roughness. Therefore, the influence of surface roughness on the corrosion failure progress and mechanism of the MAO coated ZM5 Mg alloy has been investigated. The microstructure, bonding strength, and corrosion resistance of the MAO coatings were studied by SEM, LSCM, bonding strength measurement, and electrochemical test. The results showed that the surface roughness affects the porosity and bonding strength of the coatings. While it had little effect on the thickness and chemical composition of the MAO coating. Due to the high surface porosity, the coating of the grooved sample had poor corrosion resistance in the initial immersion. But, after a long-time immersion, the grooved sample was still protected by the coating, while the smooth sample showed severe damage. The strong bonding strength between the coating and groove sample was the key factor for enhancing the corrosion resistance of MAO coated ZM5 Mg alloy. [ABSTRACT FROM AUTHOR]