Initial Stages of Al-AM60-Modified Surface of Magnesium Alloy Activity Exposed to Simulated Marine Environment

The surface of AM60 magnesium alloy was modified with Al-nanocoating ~65.62 nm, using DC magnetron sputtering to enhance its resistance to degradation under aggressive marine ambience. The sputtered Al film showed adhesion to the α-Mg matrix, covering the dispersed particles of the β-Mg17Al12 secondary phase. The aluminum nanofilm was composed of (111) and (200) crystal planes of metallic aluminum (Al0) and Al2O3 (Al3+). After 30 days of immersion in a simulated marine environment (SME, pH 7.8), the Al-AM60 maintained a lower alkaline value (pH~8.13) of SME than that of uncoated AM60, attributed to α-Mg electrochemical oxidation to Al2O3 and its posterior dissolution, consuming OH− ions. Consequently, the concentration of the released Mg2+ ions from the Al-AM60 surface was reduced ~2.3 times (~15 mg L−1). The Rp (polarization resistance), as inversely proportional to the corrosion current, was extracted from the EIS impedance data fitted to an equivalent electrical circuit. After 30 days in SME solution, the Rp value of the Al-AM60 modified surface was ~3.5 times higher than that of AM60 (~15.46 kΩ cm2), confirming that the sputtered aluminum nano-deposit layer can hinder the corrosion process. These reported findings indicated that sputtered Al nano-coatings can mitigate the surface degradation of Mg-Al alloys in saline aggressive marine environments.