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Micro-arc oxidation (MAO) coatings were prepared on the AZ31 Mg alloy under the constant/gradient current control modes. The effects of current output modes on the growth rate, energy consumption, microstructure, and corrosion resistance of MAO coatings were studied. The results shows that the current step-down mode (G852) exhibited a lower unit energy consumption than the constant current mode (C5) and the current step-up mode (G258), even though the same average current density current was used during MAO process. Meanwhile, the G852 is conducive to a thick and dense coating, resulting in a better corrosion resistance. The method of energy saving preparation of corrosion resistant MAO coating by adjusting the current mode is of great significance for practical production.

This study aimed to prepare self-lubricating micro-arc oxidation (MAO)/graphite composite coatings on 6061 aluminium alloy by adding graphite nanoparticles into an alkaline electrolyte during the MAO process. The microstructure, phase composition and element distribution of MAO coatings were studied using Scanning Electron Microscope (SEM), x-ray diffraction (XRD) and Energy Dispersive Spectrometer (EDS). The results showed that graphite nanoparticles can be coated uniformly in the MAO coatings, and the porosity and surface roughness of the MAO coatings were reduced by the addition of graphite nanoparticles. However, when the content of graphite nanoparticles was more than 6 g l ^−1 , graphite aggregation occurred. The wear resistance of the coatings was investigated using the ball-on-disk friction tester. After incorporating the graphite nanoparticles, the MAO coatings showed excellent self-lubricating properties and a reduction in the friction coefficient during the wear process. In addition, the MAO coatings showed the best result with the addition of 4 g l ^−1 graphite nanoparticles compared with all the other composite coatings under investigation. In conclusion, the incorporation of graphite nanoparticles improved the wear properties of the MAO coatings.

Micro-arc oxidation (MAO) coating was initially prepared on 6061 Al alloy, and subsequently coated with Ag using magnetron sputtering. Laser beam scan (LBS) treatments were then applied to infiltrate the sputtered Ag into the MAO coating in order to simulate the corrosion behaviour of the MAO coating during the neutral salt spray test (NSST). Cross-sectional morphologies and Ag element distribution maps were studied by using the field emission scanning electron microscopy (FESEM) on the MAO-Ag coated samples after LBS infiltration. The results showed that there existed the micro-cracks with tree-root or lightning shape within the MAO coating. Interconnected aggregates, including micro-pores, large cavities far beneath the surface and tree-root like micro-cracks, served as complex corrosion channels during salt spray corrosion. Through these corrosion channels, the salt spray penetrated gradually into the interface between the MAO coating and the original Al substrate, thus causing corrosion of the Al substrate during the NSST. The LBS treatment is presented as a method to explore the subtle micro-crack and pore channels associated to the MAO coating and to provide information that paves the way towards understanding of corrosion phenomena in these porous systems.

The magnesium alloys attract the light-weight manufacture due to its high strength to weight ratio, however the poor corrosion resistance limits the application in automobile industry. The Micro-arc Composite Ceramic (MCC) coatings on AZ91D magnesium alloys were prepared by Micro-arc Oxidation (MAO) and electrophoresis technologies. The microstructure, corrosion resistance, abrasion resistance, stone impact resistance and adhesion of MCC coatings were studied respectively. The cross section morphologies showed that the outer organic coating was filled into the hole on surface of MAO coating, and it acted as a shelter against corrosive products. The copper-accelerated acetic acid salt spray Test, abrasion resistance test, stone impact resistance test, thermal shock resistance test and adhesion test were used to evaluate the protective characterization by the third testing organization which approved by GM. The test results showed the composite coatings meet all the requirements. The MCC coating on Mg presents excellent properties, and it is a promising surface treatment technology on magnesium alloys for production vehicles.

Micro-arc oxidation (MAO) was performed on AZ31 and AZ91 Mg alloys to explore the relationship between Mg substrates and corrosion behaviors of resultant coatings. The microstructure and long-term corrosion performance of the two coatings were investigated. Results showed that MAO coating on AZ91 alloy provided a longer-term corrosion protection to substrate than that on AZ31 alloy, despite having similar microstructure and phase composition. However, once corrosion occurred, the corrosion area of MAO coating on AZ91 alloy enlarged at a faster rate compared to that on AZ31 alloy during immersion tests, and their corrosion morphologies were different. Based on the corrosion features of Mg substrates and MAO coatings, roles of substrates on the corrosion processes of coatings were analyzed.

Two kinds of metal oxide coatings were fabricated on 7050 Al alloy by hard anodization (HA) and micro-arc oxidation (MAO) techniques. The microstructure, phase composition, and corrosion behavior of the two coatings were studied by scanning electron microscopy, X-ray diffraction, and corrosion tests, respectively. When compared with the HA coating, the MAO one was more effective to isolate the substrate from the corrosive environment. In addition, as confirmed by electrochemical tests, the MAO coating was of better corrosion resistance than the HA coating. Furthermore, it was revealed by neutral salt spray test that the MAO coating could protect substrate alloy over 1140 h, while the HA coating can only protect substrate alloy for 46 h due to the amorphous composition and through thickness defects (micro-pores and micro-cracks).