Cathodic electrophoretic deposited HA-rGO-ZnO ternary composite coatings on ZK60 magnesium alloy for enhanced corrosion stability

HA-rGO-ZnO ternary composite coatings were successfully prepared on ZK60 magnesium alloy using cathodic electrophoretic deposition method. XRD analysis proved the addition of ZnO nanoparticles induced a significantly reduced crystallinity in hydroxyapatite and the tensile strain values of HA-rGO-ZnO composite coatings gradually decreased as the content of ZnO increased. SEM analyses revealed that the HA and ZnO nanoparticles were anchored on rGO nanosheets and a closely-packed network of recrystallization needle-like ZnO and mineralization HA crystals was formed on the surface of HA-rGO-ZnO coated sample. The resulting composite coating exhibited a uniform and compact HA-rGO-16ZnO composite coating, with well adhered to the ZK60 magnesium alloy substrate. The HA-rGO-16ZnO coated sample exhibited the highest corrosion resistance with lowest icorr (1.12 × 10−6 A/cm2) and the highest Ecorr (−1.43 V/SCE) value when compared to HA-rGO-14ZnO and HA-rGO-18ZnO samples after immersion in a SBF for 10 min. Compared to HA-rGO-ZnO coated samples after 10 min of immersion in SBF, HA-rGO-ZnO coated samples after 3 days of immersion in SBF exhibited a remarkably improved corrosion resistance and rapid inducing of the apatite layer precipitated on the surface of the composite coatings. The microstructure and composition for the coated samples after 3 days of immersion in SBF also confirm that the presence of a apatite layer on the composite coatings. HA-rGO-18ZnO coated samples after 3 days of immersion in SBF showed the lowest icorr value, which indicating HA-rGO-18ZnO ternary composite coatings dramatically improved the formation ability of the apatite layer and led to an enhancement in the bioactivity. Accordingly, it is believed that the HA-rGO composite coating incorporated with ZnO will be a potential candidate for bone biomedical applications.