The electrochemical corrosion characteristics of AZ31 and AZ61 magnesium alloys were analyzed in terms of potentiodynamic tests and electrochemical impedance spectroscopy. The influence of the solution composition and material surface finish was examined also through the analysis of corrosion products created on the samples’ surface after electrochemical measurements in terms of scanning electron microscopy using energy-dispersive spectroscopy. Obtained data revealed the differences in the response of the magnesium alloys to enriched Hank’s Balanced Salt Solution—HBSS+ (with Mg²⁺ and Ca²⁺ ions) and Hank’s Balanced Salt Solution—HBSS (without Mg²⁺ and Ca²⁺ ions). Both examined alloys exhibited better corrosion resistance from the thermodynamic and kinetic point of view in the enriched HBSS+. AZ61 magnesium alloy reached higher values of polarization resistance than AZ31 magnesium alloy in both the used corrosion solutions. Phosphate-based corrosion products were characteristic for the AZ31 and AZ61 alloys tested in the HBSS (without Mg²⁺ and Ca²⁺ ions). The combination of phosphate-based corrosion products and clusters of MgO and Mg(OH)₂ was typical for the surface of samples tested in the enriched HBSS+ (with Mg²⁺ and Ca²⁺ ions). Pitting corrosion attack was observed only in the case of enriched HBSS+.

Linear polarization is a potentiodynamic method used for electrochemical characterization of materials. Obtained values of corrosion potential and corrosion current density offer information about material behavior in corrosion environments from the thermodynamic and kinetic points of view, respectively. The present study offers a comparison of applications of the linear polarization method (from −100 mV to +200 mV vs. E_OCP), the cathodic polarization of the specimen (−100 mV vs. E_OCP), and the anodic polarization of the specimen (+100 mV vs. E_OCP), and a discussion of the differences in the obtained values of the electrochemical characteristics of cast AZ91 magnesium alloy. The corrosion current density obtained by cathodic polarization was similar to the corrosion current density obtained by linear polarization, while a lower value was obtained by anodic polarization. Signs of corrosion attack were observed only in the case of linear polarization including cathodic and anodic polarization of the specimen.

Magnesium with its mechanical properties and nontoxicity is predetermined as a material for biomedical applications; however, its high reactivity is a limiting factor for its usage. Powder metallurgy is one of the promising methods for the enhancement of material mechanical properties and, due to the introduced plastic deformation, can also have a positive influence on corrosion resistance. Pure magnesium samples were prepared via powder metallurgy. Compacting pressures from 100 MPa to 500 MPa were used for samples’ preparation at room temperature and elevated temperatures. The microstructure of the obtained compacts was analyzed in terms of microscopy. The three-point bendisng test and microhardness testing were adopted to define the compacts’ mechanical properties, discussing the results with respect to fractographic analysis. Electrochemical corrosion properties analyzed with electrochemical impedance spectroscopy carried out in HBSS (Hank’s Balanced Salt Solution) and enriched HBSS were correlated with the metallographic analysis of the corrosion process. Cold compacted materials were very brittle with low strength (up to 50 MPa) and microhardness (up to 50 HV (load: 0.025 kg)) and degraded rapidly in both solutions. Hot pressed materials yielded much higher strength (up to 250 MPa) and microhardness (up to 65 HV (load: 0.025 kg)), and the electrochemical characteristics were significantly better when compared to the cold compacted samples. Temperatures of 300 °C and 400 °C and high compacting pressures from 300 MPa to 500 MPa had a positive influence on material bonding, mechanical and electrochemical properties. A compacting temperature of 500 °C had a detrimental effect on material compaction when using pressure above 200 MPa.

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.