Novel Phosphate Conversion Coating with Superior Corrosion Resistance on the Mg-Al-RE Alloy Based on the Introduction of Silane

A novel chemical conversion method based on an aqueous electrolyte solution containing hydrolyzed silane as a crucial film-forming agent has been developed successfully. An organic/inorganic composite coating with superior corrosion protection was fabricated on the Mg-Al-RE alloy. The micro-morphology and chemical composition of the coating were examined using scanning electron microscopy, X-ray diffraction, and energy-dispersive X-ray spectroscopy. The prepared conversion coating possesses a double-layer structure, with a dense bottom layer and a loose outer layer containing microcracks. In addition, the anti-corrosion capacity of various samples was evaluated using salt spray, hydrogen evolution, and electrochemical tests. The analysis revealed that the samples converted by 3-aminopropyl triethoxysilane (APTES)-phosphate solution possessed a higher corrosion resistance. Compared to the blank sample, a 2 orders of magnitude reduction in icorr (6.678 × 10-7 A/cm2) and a 1.360 V improvement in Ecorr were observed. The MPCC-Si sample exhibited the lowest hydrogen evolution rate, indicating the best corrosion protection. Also, the rust grade could still reach 7 after 72 h of the neutral salt spray test.