Corrosion Challenges and Surface Protection Strategies for Magnesium Alloys

TANG Rui; LI Chunyan; YANG Longpeng; TANG Yunlong; WANG Xinhua; NAN Hongbing; ZHAO Erxiang; KOU Shengzhong

doi:10.16490/j.cnki.issn.1001-3660.2026.08.002

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Surface Technology ›› 2026, Vol. 55 ›› Issue (8) : 18-35. DOI: 10.16490/j.cnki.issn.1001-3660.2026.08.002

Corrosion and Protection

Corrosion Challenges and Surface Protection Strategies for Magnesium Alloys

TANG Rui^1a, LI Chunyan^1a,1b,2,*, YANG Longpeng^1a, TANG Yunlong^1a, WANG Xinhua^1a, NAN Hongbing^1a, ZHAO Erxiang³, KOU Shengzhong^1a,1b

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Abstract

As a lightweight, high-strength, and fully recyclable "green engineering material", magnesium alloys have become a transformative solution in modern manufacturing, demonstrating significant potential across various industrial sectors such as automotive production, aerospace engineering, and consumer electronics. Their unique combination of low density (approximately 1.74 g/cm³, only two-thirds that of aluminum and one-quarter that of steel), high specific strength, and excellent damping capacity (providing superior vibration absorption compared to many structural metals) makes them an ideal candidate for lightweight structural design. However, magnesium, as an alkaline earth metal, exhibits high chemical reactivity (with a standard electrode potential of -2.37 V vs. the standard hydrogen electrode), which leads to a major limitation: poor corrosion resistance. This makes magnesium alloys highly vulnerable to severe degradation in aggressive environments, including high-humidity atmospheres (common in coastal or tropical regions), chloride-containing media (e.g., seawater or road deicing salts), and even mild acidic conditions (such as those encountered in industrial cleaning processes). Under these circumstances, unprotected magnesium alloys are prone to rapid corrosion. In recent years, spurred by the growing demand for sustainable and lightweight materials, considerable progress has been made in research on corrosion protection technologies for magnesium alloys. This article provides a systematic review of the corrosion challenges faced by magnesium alloys and the corresponding surface protection strategies, aiming to bridging the gap between their theoretical potential and practical applications. It begins by analyzing the fundamental corrosion mechanisms that underlie the poor corrosion resistance of magnesium alloys. Firstly, the low electrode potential of magnesium causes it to act as an anode when coupled with other metals (e.g., steel or copper), accelerating electrochemical corrosion; Secondly, the native oxide film that forms on magnesium in air is inherently porous and unstable, unlike the dense, protective layer on aluminum. This porous structure fails to effectively block moisture, oxygen, or chloride ions, resulting in continuous oxidation of the magnesium matrix and the formation of non-protective corrosion products (e.g., Mg(OH)₂), which further exacerbates material degradation. Building on these mechanisms, the article elaborates on the various corrosion types that magnesium alloys may experience in actual environments. Under atmospheric conditions, they typically undergo general corrosion, a slow and uniform degradation of the entire surface, a process accelerated by high humidity. In seawater or chloride-rich environments, pitting corrosion is more common. Chloride ions accumulate at surface inhomogeneities (e.g., grain boundaries or microcracks), the oxide film and forming small but deep pits that significantly weaken the material. In multi-material systems (e.g., magnesium-steel joints in automotive applications), galvanic corrosion is another critical issue, where the electrochemical potential difference between metals accelerates magnesium dissolution. Stress corrosion cracking (SCC) also poses a serious threat to load-bearing components (e.g., in aerospace structures), as the combined action of mechanical stress and corrosive attack can lead to sudden and catastrophic failures. The review then summarizes recent advances in surface modification technologies for magnesium alloys. Chemical conversion treatments such as chromating and phosphating involve immersing magnesium alloys in chemical solutions to form thin inorganic films (e.g., chromate or phosphate layers). Electroplating and electroless plating are employed to deposit metallic coatings (e.g., nickel, copper, or zinc) that enhance corrosion resistance; electroless plating is particularly suitable for complex geometries due to its ability to form uniform coatings without an external current. Anodization and micro-arc oxidation (MAO) are among the most promising approaches. In anodization, an electric field is used to thicken the surface oxide layer, while in MAO, high-voltage micro-discharges are utilized to produce dense, ceramic-like oxide coatings (typically 5-100 μm thick) that offer excellent corrosion and wear resistance, making them ideal for high-performance applications such as aerospace components. Other techniques include laser surface treatment (which modifies the surface microstructure to improve oxidation resistance), thermal spraying (depositing metal or ceramic coatings via high-temperature jets), cold spraying (a low-temperature alternative that minimizes thermal damage), and organic coatings (e.g., epoxy or polyurethane films that provide a physical barrier against corrosion and are widely used in consumer electronics for both protection and aesthetics). All these methods aim to form dense, strongly adherent protective layers that isolate the magnesium substrate from corrosive environments, thereby extending its service life in demanding applications. Finally, the article discusses the prospects for applying these surface protection technologies and suggests future research directions, including: first, improving the inherent properties of magnesium alloys by reducing microstructural defects to develop grades with intrinsically better corrosion resistance; and second, designing multi-layer composite coatings (e.g., combining MAO with organic layers to enhance adhesion and overall performance). This review is intended to serve as a reference for researchers and engineers, supporting the refinement of existing technologies and fostering innovation. Ultimately, it aims to facilitate safer, more reliable, and broader engineering use of magnesium alloys in the transition toward a lighter and more sustainable future. Integrate the synergy between materials, processes, and environments, and tackle the diverse challenges of magnesium alloys in various fields and under different environmental conditions, thereby fully preparing for their large-scale application in broader domains.

Key words

magnesium alloys / corrosion / surface modification / anti-corrosion technology

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TANG Rui, LI Chunyan, YANG Longpeng, TANG Yunlong, WANG Xinhua, NAN Hongbing, ZHAO Erxiang, KOU Shengzhong. Corrosion Challenges and Surface Protection Strategies for Magnesium Alloys[J]. Surface Technology. 2026, 55(8): 18-35

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Funding

The National Natural Science Foundation of China (52261032, 51861021); The Key Research and Development Program of Gansu Province (21YF5GA074); The Basic Public Welfare Research Program of Zhejiang Province (LGG22E010008); and the Basic Public Welfare Scientific Research Project of Wenzhou City (G2023020)