Fabrication and Properties of Micro-arc Oxidation/Polyimide/CeO2 Composite Coating on Mg Alloys

CHEN Liyan; WEI Xiaoqing; WANG Chenfeng; HAO Xiaofei; LI Yan; ZHAO Xingchuan

doi:10.16490/j.cnki.issn.1001-3660.2026.12.005

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Surface Technology ›› 2026, Vol. 55 ›› Issue (12) : 71-83. DOI: 10.16490/j.cnki.issn.1001-3660.2026.12.005

Corrosion and Protection

Fabrication and Properties of Micro-arc Oxidation/Polyimide/CeO₂ Composite Coating on Mg Alloys

CHEN Liyan, WEI Xiaoqing, WANG Chenfeng, HAO Xiaofei, LI Yan^*, ZHAO Xingchuan^*

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Abstract

The application of Mg alloys in lightweight structures for transportation and electronics is expanding due to their low density. However, their poor corrosion resistance, stemming from high chemical reactivity, remains a major obstacle. Micro-arc oxidation (MAO) is a common surface treatment that improves hardness and wear resistance, but the inherent micro-pores and micro-cracks in the ceramic layer act as pathways for corrosive agents, leading to eventual coating failure and substrate corrosion, which limits long-term performance. To address the issue of insufficient long-term corrosion resistance and wear resistance of MAO coatings on Mg alloys caused by the presence of micropores and microcracks, this study aims to develop a novel polyimide (PI)/cerium dioxide (CeO₂) composite coating to seal the defects in the MAO layer and enhance its comprehensive protective performance. First, CeO₂ particles are dispersed in a polyimide solution. Subsequently, this composite solution is applied to the surface that has undergone MAO treatment, successfully preparing a coating with excellent corrosion resistance and wear resistance. Scanning electron microscopy, X-ray diffraction, electrochemical tests, salt spray tests, and friction and wear tests are employed to systematically characterize the microstructure, corrosion resistance, and wear resistance of the coating. The microstructure analysis indicates that the PI layer completely fills the pores of the MAO layer, forming a dense, smooth, and hydrophobic surface (contact angle >110°). Electrochemical tests reveal that PI sealing and CeO₂doping significantly improve the protective performance of the coating: the MAO/PI-CeO₂coating exhibits the most positive corrosion potential and the lowest corrosion current density, far superior to that of single MAO and MAO/PI coatings. Salt spray tests further confirm that the MAO/PI-CeO₂coating shows only slight local corrosion after 40 days, demonstrating excellent long-term stability. Additionally, the introduction of CeO₂decreases the wear depth, significantly enhancing the wear resistance. Analysis of the wear tracks using 3D profilometry confirms a substantial decrease in both wear width and depth, underscoring the coating's superior resistance to abrasive and adhesive wear. The exceptional performance is attributed to a synergistic mechanism. The PI matrix acts as a dense, continuous physical barrier that blocks the penetration of electrolytes. Simultaneously, the dispersed CeO₂nanoparticles play a dual role: they further densify the polymer matrix, reducing intrinsic micro-defects, and provide an active chemical inhibition function. Upon exposure, Ce³⁺/Ce⁴⁺ions can be released and migrate to local cathodic sites, where they react with hydroxyl ions to form insoluble cerium hydroxide/oxide precipitates, which effectively block active corrosion sites and hinder further cathodic reactions, imparting a self-healing capability to the coating system. The PI/CeO₂composite coating successfully prepared in this study can effectively seal the microdefects in the MAO layer, significantly improving the long-term corrosion resistance, wear resistance, and hydrophobicity of the MAO coating on Mg alloys. This multifunctional composite coating presents a promising and robust surface engineering solution for extending the service life of Mg alloy components in demanding corrosive and mechanically abrasive environments.

Key words

Mg alloy / micro-arc oxidation / CeO₂ / polyimide / corrosion and wear resistance

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CHEN Liyan, WEI Xiaoqing, WANG Chenfeng, HAO Xiaofei, LI Yan, ZHAO Xingchuan. Fabrication and Properties of Micro-arc Oxidation/Polyimide/CeO₂ Composite Coating on Mg Alloys[J]. Surface Technology. 2026, 55(12): 71-83

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Funding

National Natural Science Foundation of China (52501096); Shandong Provincial Natural Science Foundation (ZR2025QC513); Liaocheng University Students Innovation Plan (cxcy2025016)