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This randomized trial demonstrates a new coating reduces galvanic corrosion in magnesium alloys, suggesting improved industrial performance.
Galvanic corrosion is one of the most critical huddles that must be overcome for magnesium (Mg) alloys in industrial applications. This paper reports on a Zn-3Al-2Mg alloy coating rapidly cast on a Mg alloy WE43. The new thick coating metallurgically fused with the substrate without altering the substrate microstructure underneath had controlled thickness, desired surface quality and expected geometry. It even exhibited an impressive passivating behavior in 3.5 wt.% NaCl. In its multilayered microstructure, the high melting point hard barrier made the coating wear-resistant. More importantly, the highly self-corrosion-resistant coating could satisfactorily retard the galvanic corrosion caused by coupled steel Q235. These favorable coating features shred a light on the solution of the stubborn galvanic corrosion of Mg alloys in engineering. Based on microstructural and electrochemical measurements, a model is proposed for the coating formation, with which the great protectiveness and anti-galvanic behavior of the coating are also successfully explained.
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Yang et al. (2026) studied this question.
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