Influence of Titanium Coating Thickness on Microstructure, Residual Stress, and Corrosion Behaviour of Magnetron-Sputtered WE43 Magnesium Alloy

Magnesium alloys are attractive for temporary orthopaedic applications because of their biodegradability and favourable mechanical properties; however, their relatively rapid degradation under physiological conditions remains a challenge. In this study, the microstructural evolution, residual stress and electrochemical corrosion behaviour of WE43, a rare earth-containing magnesium alloy with yttrium, neodymium and zirconium as alloying elements, coated with titanium, were investigated as functions of deposition time using direct-current magnetron sputtering. Titanium coatings were deposited for 1, 1.5, 2 and 3 h, producing coating thicknesses of approximately 500, 650, 1000 and 1400 nm, respectively. Field-emission scanning electron microscopy, atomic force microscopy and grazing-incidence X-ray diffraction revealed progressive changes from fine-grained to dense and, subsequently, coarse-grained morphologies with increasing deposition time. The 2 h coating exhibited the largest crystallite size (27.17 ± 3.42 nm) and a moderate compressive residual stress of 605.3 ± 15.11 MPa. Potentiodynamic polarisation measurements showed that the 2 h coating produced the lowest corrosion current density (0.133 ± 0.026 mA/cm2) and calculated corrosion rate (2.93 ± 0.57 mm/year), representing a 67% reduction relative to independently measured, uncoated WE43 (8.87 ± 1.11 mm/year). The 3 h coating exhibited a higher compressive residual stress of 992.4 ± 21.7 MPa and a higher corrosion rate of 4.81 ± 0.74 mm/year, accompanied by localised microcracking after corrosion testing. Contact-angle measurements performed on the uncoated alloy and the 2 h coating showed an increase from 75.0 ± 2.1° to 83.0 ± 1.8°. Overall, the results indicated that corrosion performance was governed by the combined effects of coating morphology, crystallographic development and residual stress, with the 2 h deposition condition providing the most favourable balance under the present experimental conditions.