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A continuous intermetallic compound coating was fabricated on AZ91D magnesium alloy via heat treatment at 400 °C in AlCl3-NaCl molten salts for 10 h. The microstructure and composition of the coating were characterized by scanning electron microscope and energy dispersive X-ray spectrometry. The results showed that the coating has a two-layer structure (the outer Mg2Al3 phase layer and the inner Mg17Al12 phase layer) up to 37 μm thick with compact and planar interfaces between the layers and the substrate. The corrosion property of the coating was investigated using electrochemical impedance spectroscopy (EIS) and two localized electrochemical techniques, i.e., localized electrochemical impedance spectroscopy (LEIS) and scanning vibrating electrode technique (SVET). The charge transfer resistance (Rct) of the Al-alloyed coating was 2119 Ω cm2. The localized impedance and current density maps obtained through LEIS and SVET indicate not only significantly improved corrosion resistance (the impedance modulus increased by one order of magnitude and the current density decreased to approximately 3.8%, compared with the substrate) but also defect-free surface condition.

One-Step Fabrication and Localized Electrochemical Characterization of Continuous Al-Alloyed Intermetallic Surface Layer on Magnesium Alloy