Formation of Composite Coatings of Layered Double Hydroxide Particles and Hydroxide Gel by Electrophoretic Deposition on Mg Alloy and Corrosion Resistance

To improve the corrosion resistance of Mg alloys, composite coatings of layered double hydroxide intercalated with carbonate (LDH-CO3 , hydrotalcite) particles and magnesium and aluminum hydroxide gel were formed on AZ31 Mg alloy by electrophoretic deposition (EPD) using the LDH-CO3 suspension with Mg(NO3)2 and Al(NO3)3 in total of 1.25-125 mmol/L. Wet-dry cyclic corrosion tests were performed for the coated specimens after ultrasonication. LDH-CO3 particle-rich layer and magnesium and aluminum hydroxide gel-rich layer almost alternately piled up to form a composite layer. The hydroxide gel adhered the particles together and to the substrate. At the bottom of the composite layer, flake-shape LDH-structured substance densely covered the substrate surface. The coverage and thickness of the composite layer increased from sub-micrometers to 30 & mu;m with an increase of Mg and Al ion concentrations of the suspension. By ultrasonication, parts of the composite layer delaminated to expose the LDH-structured substance layer, while the coverage by the remaining composite layer increased with an increase of Mg and Al ion concentrations. The LDH-CO3 particles and hydroxide gel composite coatings prevented corrosion initiation even in the areas where the LDH-structured substance layer was exposed.