Simulation of salt spray corrosion behaviour of micro-arc oxidation coating by laser induced Ag infiltration

Abstract

Abstract Micro-arc oxidation (MAO) coating was initially prepared on 6061 Al alloy, and subsequently coated with Ag using magnetron sputtering. Laser beam scan (LBS) treatments were then applied to infiltrate the sputtered Ag into the MAO coating in order to simulate the corrosion behaviour of the MAO coating during the neutral salt spray test (NSST). Cross-sectional morphologies and Ag element distribution maps were studied by using the field emission scanning electron microscopy (FESEM) on the MAO-Ag coated samples after LBS infiltration. The results showed that there existed the micro-cracks with tree-root or lightning shape within the MAO coating. Interconnected aggregates, including micro-pores, large cavities far beneath the surface and tree-root like micro-cracks, served as complex corrosion channels during salt spray corrosion. Through these corrosion channels, the salt spray penetrated gradually into the interface between the MAO coating and the original Al substrate, thus causing corrosion of the Al substrate during the NSST. The LBS treatment is presented as a method to explore the subtle micro-crack and pore channels associated to the MAO coating and to provide information that paves the way towards understanding of corrosion phenomena in these porous systems.