In this work, the composition of an electrolyte was selected and optimized to induce the formation of hydroxyapatite during Plasma electrolytic oxidation (PEO) treatment on an AZ31 alloy for application in bioabsorbable implants. In detail, the PEO process, called PEO-BIO (Plasma Electrolytic Oxidation-Biocompatible), was performed using a silicate-phosphate-based electrolyte with the addition of calcium oxide in direct-current mode using high current densities and short treatment times. For comparison, a known PEO process for producing anticorrosive coatings, called standard, was applied on the same alloy. The coatings were characterized by scanning electron microscopy (SEM), X-ray diffraction (XRD) and XPS analyses. The corrosion performance was evaluated in simulated body fluid (SBF) at 37 °C. The coating produced on the PEO-BIO sample was porous and thicker than the standard PEO one, with zones enriched in Ca and P. The XRD analysis showed the formation of hydroxyapatite and calcium oxides in addition to magnesium-silicon oxide and magnesium oxide in the PEO-BIO sample. The corrosion resistance of PEO-BIO sample was comparable with that of a traditional PEO treated sample, and higher than that of the untreated alloy.

In this work, plasma electrolytic oxidation (PEO) process was applied on AlSi10Mg samples, produced with laser powder bed fusion (L-PBF), in the as printed condition and after different heat treatments, and, for comparison, on as-cast samples of AlSi10Mg. PEO process was performed in direct-current mode using high current densities and short time in a basic silicate electrolyte. For the first time, the effects of silicon morphology in L-PBF AlSi10Mg samples, in as printed condition and after different heat treatments, on the obtained PEO coating were investigated in terms of microstructure and corrosion properties. The microstructure of the substrate was characterized with optical and electron microscopy observations (optical microscopy OM, scanning electron microscopy SEM, and transmission electron microscopy TEM) and with X-ray diffraction (XRD). The analysis showed that heat treatments of annealing and solution treating modified the morphology and distribution of silicon in the samples obtained through L-PBF. The PEO coated samples were characterized with SEM, both on the surface and in the cross-section, and compositional analysis were performed with energy dispersive spectroscopy (EDS) analysis and elemental mapping. The coatings were also analyzed with XRD and the corrosion properties evaluated through electrochemical impedance spectroscopy (EIS) tests. Also microhardness tests were performed on the substrates and on the coatings. The microstructure of the coatings was strongly influenced by the silicon distribution. In particular, a non-uniform distribution of silicon and the presence of iron-rich intermetallic (obtained in the as-cast and solution treated samples) induced the formation of more porous and thinner coatings in comparison with the ones obtained in the as printed and annealed samples. The not-uniform silicon distribution produced a not-homogenous distribution of silicon into the coatings. The particular cellular structure of the as printed sample induced the formation of a coating with a higher amorphous fraction, in comparison with the ones produced on the other samples. The higher thickness and lower porosity of the coatings obtained on the annealed and as printed samples resulted in an increase of the corrosion resistance.

The hydrocarbon industry constantly requires a better understanding of stainless-steel welding metallurgy. Despite the fact that gas metal arc welding (GMAW) is one of the most commonly employed welding processes in the petrochemical industry, the process is characterized by the presence of a high number of variables to control in order to obtain components that are dimensionally repeatable and satisfy the functional requirements. In particular, corrosion is still a phenomenon that highly affects the performance of the exposed materials, and special attention must be paid when welding is applied. In this study, the real operating conditions of petrochemical industry were reproduced through an accelerated test in a corrosion reactor at 70 °C for 600 h, exposing robotic GMAW samples free of defects with suitable geometry. The results show that, even if duplex stainless steels are characterized for being more corrosion resistant than other stainless steels, under these conditions it was possible to identify microstructural damage. In detail was found that the corrosion properties were strongly related to the heat input during welding and that the best corrosion properties can be obtained with the higher heat input.