Electrophoretic Deposition of 3YSZ Coating on AZ91D Alloy Using Al and Ni-P Interlayers

Electrophoretic deposition was used in order to apply the zirconia stabilized by 3 mol% Y 2 O 3 onto the surface of the magnesium alloy AZ91D. Two different interlayers which were including aluminum layer and Ni-P layer were prepared between the AZ91D surface and YSZ coating and the effect of them on the quality of YSZ coating was investigated. The surface morphologies of the coatings were studied by scanning electron microscopy, and their compositions were determined by x-ray diffraction. The corrosion resistance of the coatings was evaluated by electrochemical impedance spectroscopy in 3.5% NaCl neutral solution. Also, the stability of coating was investigated by the Rockwell C indentation test. The results showed that the YSZ coating applied onto different interlayers on AZ91D improves the corrosion resistance of this alloy due to increase in charge-transfer resistance of the AZ91D surface. Also, the aluminum interlayer has a favorable effect on the densification of the coating by formation of aluminum oxide. Furthermore, the corrosion resistance of AZ91D that coated by YSZ and aluminum layer was improved compared to that of coated AZ91D with YSZ and Ni-P layer. The presence of interlayers can make the stability of the YSZ coating improved on the surface of AZ91D.