One-step Zn-based composites fabrication via double glow plasma for synergistic mechanical-corrosion control and interface mechanism elucidation

In this work, a one‐step double glow plasma surface alloying(DGPSA) technique was employed to fabricate Zn‐based composites reinforced with columnar iron phases, enabling controllable degradation rates. The composite features a surface-covered Ta transition layer with a content of up to 66 wt%, while the sintered interior demonstrates strong bonding between the Zn matrix and iron reinforcement. Experimental results revealed that the Zn-8Fe composite achieves a compressive yield strength (CYS) of 401 MPa and an elastic modulus increased to 7581 MPa. Immersion tests further demonstrated that the sample with a 40 wt% Ta coating exhibits a corrosion weight loss rate of only 6.5 × 10 -4 g·cm -2 ·day -1 , representing a 36.1% reduction compared to pure Zn (1.02 × 10 -3 g·cm -2 ·day -1 ). Molecular dynamics simulations elucidate the sintering mechanism at the Zn-Fe interface. The Zn matrix, characterized by its high thermal expansion coefficient, effectively fills the initial interfacial gaps during thermal cycling. The iron reinforcement exhibits a high thermal conductivity of 4.62 × 10 -2 W/(m·K), which further enhances interfacial bonding, achieving a pull-out strength of up to 2.40 × 10 -7 N. This study provided both experimental and theoretical support for the design of biodegradable Zn‐based implant materials, offering a breakthrough strategy for biomedical applications of Zn alloys.