Plasma Electrolytic Oxidation (PEO) was applied to extruded ZM21 Mg alloys to improve their corrosion resistance in a chloride-containing environment. PEO was carried out in DC mode and voltage control in a fluoride-free electrolyte. Potentiodynamic polarization tests in 3.5 wt.% NaCl aqueous solution and neutral salt spray (NSS) tests were carried out. Microstructural and profilometric characterization, as well as NSS tests were performed in different conditions: (i) bare ZM21, (ii) PEO-treated ZM21, (iii) powder-coated ZM21 (without PEO interlayer), and (iv) PEO-treated ZM21 with powder coating top layer (carboxyl-functionalized polyester resin). The PEO + powder coating double layer was identified as the best-performing corrosion protection.
Keywords: anodizing; corrosion resistance; fluoride free electrolyte; micro arc oxidation; salt spray; spark anodization.