Application-Driven Review of PEO/MAO-Based Composite Coatings for Magnesium Alloys: Functional Architectures, Failure Mechanisms and Validation Strategies

Magnesium alloys are used or considered for lightweight structures and biodegradable implants, but high electrochemical activity, limited wear resistance, and localized corrosion still limit their service reliability. Plasma electrolytic oxidation (PEO), also called micro-arc oxidation (MAO), forms an adherent ceramic scaffold. Discharge channels, interconnected pores, thermal cracks, and a mechanically weak outer layer mean that the as-formed coating is rarely a complete protective system. This review examines advanced PEO/MAO-based composite coatings through a process–structure–function lens and develops an application-oriented design framework. The discussion covers PEO/MAO process-window control, electrolyte and particle engineering, sol–gel and polymer sealing, layered double hydroxide/inhibitor systems, self-healing reservoirs, superhydrophobic and slippery interfaces, Ca-P/hydroxyapatite and polymer biofunctionalization, and duplex coatings for wear, electrical, and thermal functions. Emphasis is placed on how these modules regulate defect connectivity, mass transport, interfacial stability, damage response, tribocorrosion, and biodegradation, as well as on the evidence needed to support each claimed function. The analysis indicates that coating performance is governed not by multilayer complexity alone, but by the compatibility among the ceramic scaffold, functional module, dominant failure mode, and service-specific validation protocol. Chloride-exposed structures require durable pore sealing and active inhibition; wear-critical components require coupled corrosion–wear assessment; and biodegradable implants require a degradation window that balances corrosion moderation, cytocompatibility, biofunctionality, and residual mechanical integrity. Remaining challenges include interfacial durability, finite inhibitor reservoirs, wetting-state instability, process reproducibility, scale-up, and life-cycle impacts. The proposed process maps and validation criteria are intended to support modular, testable, and application-specific PEO/MAO surface systems for magnesium alloys.