The present study reports the effect of phosphorus content in deposited electroless nickel (Ni–P) coatings, the heat treatment on the microhardness and its microstructural characteristics, and the influence of the temperature on the microstructure of the Mg alloy substrate during the heat treatment. The deposition of Ni–P coatings was carried out in the electroless nickel bath, and the resulting P content ranged from 5.2 to 10.8 wt.%. Prepared samples were heat-treated in the muffle furnace at 400 °C for 1 h after the coating deposition. The cooling of the samples to room temperature was proceeded in the air. For as-deposited and heat-treated samples, it was determined that with the increasing P content, the microhardness was decreasing. This may be caused by the changes in the structure of the Ni–P coating. The X-ray diffraction patterns of the as-deposited Ni–P coatings showed that the microstructure changed their nature from crystalline to amorphous with the increasing P content. The heat treatment of prepared samples led to the significant increase of microhardness of Ni–P coatings. All the heat-treated samples showed the crystalline character, regardless of the P content and the presence of hard Ni₃P phase, which can have a positive effect on the increase of microhardness. The metallographic analysis showed changes of substrate microstructure after the heat treatment. The prepared coatings were uniform and with no visible defects.

This paper deals with the study of the crystallization and phase transformation of Ni-P coatings deposited on AZ91 magnesium alloy. Prepared samples were characterized in terms of surface morphology and elemental composition by means of scanning electron microscopy with energy-dispersive spectroscopy analysis. The results of X-ray diffraction analysis and differential scanning calorimetry suggested that increasing the phosphorus content caused Ni-P coatings to develop an amorphous character. The crystallization of Ni was observed at 150, 250, and 300 °C for low-, medium- and high-phosphorus coatings, respectively. The Ni crystallite size increased with increasing temperature and decreasing P content. Conversely, the presence of the Ni₃P phase was observed at a maximum peak of 320 °C for the high-phosphorus coating, whereas the crystallization of the Ni₃P phase shifted to higher temperatures with decreasing P content. The Ni₃P crystallite size increased with increasing temperature and increasing P content. An increase in microhardness due to the arrangement of Ni atoms and Ni₃P precipitation was observed. The deposition of as-deposited Ni-P coatings led to an improvement in the corrosion resistance of AZ91. However, the heat treatment of coatings resulted in a deterioration in corrosion properties due to the formation of microcracks.

Electroless low-phosphorus Ni–P coating was deposited on a wrought ZE10 magnesium alloy including an advanced pre-treatment of the material surface before deposition. Uniform Ni–P coating with an average thickness of 10 µm was formed by 95.6 wt % Ni and 4.4 wt % P. The content of Ni and P was homogeneous in the entire cross-section of the coating. Applying the Ni–P coating to the magnesium substrate, the surface microhardness increased from 60 ± 4 HV 0.025 to 690 ± 30 HV 0.025. Using the scratch test, it was determined that deposited Ni–P coating exhibits a high degree of adhesion to the magnesium substrate. Electrochemical corrosion properties of Ni–P coating were analyzed using the polarization tests in 0.1 M NaCl, while the deposited Ni–P coating showed an improvement of the corrosion resistance when compared to the ZE10 magnesium alloy. Using the scanning electron microscopy analysis, it was determined that the fine morphology of the deposited Ni–P coating did not contain visible microcavities. The absence of macrodefects due to the adequate pre-treatment before coating was reflected on the mechanism of the coated ZE10 degradation in a 0.1 M NaCl solution.

Superhydrophobic surfaces were prepared using a two-step method that involved the etching of AZ31 and AZ91 magnesium alloys and then modifying the etched alloys with stearic acid. Magnesium alloys etched with ZnCl₂ and SnCl₂ exhibited surfaces roughened with micro- and nanoscale hierarchical structures consisting of two chemically distinct regions (Zn/Zn(OH)₂ or Sn/SnO₂ and Mg(OH)₂). An optimum etching time of ten minutes was chosen for both etchants. Superhydrophobic surfaces with the highest contact angle were prepared when stearic acid reacted with the etched alloys at 50 °C for 4 h. Stearic acid was bound as zinc stearate and magnesium stearate on Mg alloys etched with ZnCl₂ and SnCl₂ solutions, respectively. The superhydrophobic process on AZ31 alloys etched with ZnCl₂ and SnCl₂ improved the corrosion resistance in phosphate buffered saline (PBS) solution compared to bare AZ31 alloy, with the use of ZnCl₂ etchant leading to better results. An improvement in the corrosion resistance of AZ91 alloy was observed when the stearic-acid-modified AZ91 alloy was etched with SnCl₂. In contrast, the use of ZnCl₂ etchant to pretreat AZ91 alloy resulted in a significant deterioration in corrosion properties compared to bare AZ91 alloy. The microstructure of the Mg alloy had an impact on the etching and modification process. On the basis of the findings, a characterization of the chemistry of etching magnesium alloys and the formation of superhydrophobic surfaces was proposed. Magnesium alloys were prepared with superhydrophobic surfaces, incorporating antibacterial metals, features which may increase their potential for use in medical applications.

The corrosion behavior of duplex Ni-P coatings deposited on AZ91 magnesium alloy was studied. The electroless deposition process of duplex Ni-P coating consisted in the preparation of low-phosphorus Ni-P coating (5.7 wt.% of P), which served as a bond coating and high-phosphorus Ni-P coating (11.5 wt.% of P) deposited on it. The duplex Ni-P coatings with the thickness of 25, 50, 75 and 100 µm were deposited on AZ91 magnesium alloy. The electrochemical corrosion behavior of coated AZ91 magnesium alloy was investigated by electrochemical impedance spectroscopy and potentiodynamic polarization method in 0.1 M NaCl. Obtained results showed a significant improvement in the corrosion resistance of coated specimens when compared to uncoated AZ91 magnesium alloy. From the results of the immersion tests in 3.5 wt.% NaCl, 10% solution of HCl and NaOH and 5% neutral salt spray, a noticeable increase in the corrosion resistance with the increasing thickness of the Ni-P coating was observed.

A progressive type of tungsten-doped DLC coating was applied to a quenched and tempered 100Cr6 steel with the aim to improve the wear and corrosion properties in simulated seawater conditions and to compare the performance to conventional DLC coating. Tungsten doping caused a shift of the corrosion potential (E_corr) to a lower negative value of −172 mV, while the conventional DLC exhibited an E_corr of −477 mV. In dry conditions, the W-DLC coefficient of friction is slightly higher than that of the conventional DLC (0.187 for the W-DLC vs. 0.137 for the DLC), but in cases of a saltwater environment, this difference becomes almost negligible (0.105 for the W-DLC vs. 0.076 for the DLC). The conventional DLC coating also started to show marks of deterioration when exposed to a combination of wear in a corrosive environment, while the W-DLC layer still maintained its integrity.