Dual-nanoparticle doping strategy for micro-arc oxidation coatings on magnesium alloys featuring synergistically enhanced wear and corrosion resistance

Hao Wu; Xinyi Guo; Xuying Xie; Weilong Xue; Kailin Zhu; Minghan Huang; Zhenghua Wu; Ji-an Feng; Zhibiao Xu; Paul K. Chu

doi:10.1016/j.apsusc.2026.166664

Dual-nanoparticle doping strategy for micro-arc oxidation coatings on magnesium alloys featuring synergistically enhanced wear and corrosion resistance

Hao Wu
, Xinyi Guo
, Xuying Xie
, Weilong Xue
, Kailin Zhu
, Minghan Huang
, Zhenghua Wu
, Ji-an Feng
, Zhibiao Xu^*
, Paul K. Chu

^*Corresponding author for this work

Research output: Journal Publications and Reviews › RGC 21 - Publication in refereed journal › peer-review

Abstract

Improving the corrosion and wear resistance of magnesium alloys is essential for extending their service lifetime in aggressive environments. Herein, a dual-nanoparticle co-doping strategy is designed to construct dense and multifunctional micro-arc oxidation (MAO) coatings on the AZ31B magnesium alloy by introducing hexagonal boron nitride nanosheets (BNNSs) and zirconia nanoparticles (ZNPs) into the electrolyte. The incorporation of these two phases modifies the discharge behavior, promoting self-sealing and generating a compact MgO-based ceramic layer with uniformly dispersed BNNSs and ZNPs. Consequently, the ZNPs/BNNSs co-doped MAO coating (ZBM) exhibits superior barrier properties, manifested by a reduction in the corrosion current density of two orders of magnitude compared to the conventional MAO coating. Furthermore, the ZBM coating has excellent self-lubricating and anti-wear properties, including a low and stable coefficient of friction less than 0.3 and a small wear rate of 4.90 × 10^-6 mm³·N⁻¹·m⁻¹. Surface and cross-sectional characterization of wear tracks reveal the formation of a continuous and dense tribo-transfer film on the worn surface. The exfoliated BNNSs facilitate shear sliding to provide solid lubrication, while the hard ZNPs act synergistically as load-bearing reinforcements to suppress plastic deformation and plowing. The results suggest an effective strategy to fabricate durable, low-friction, and corrosion-resistant coatings for Mg-based components. © 2026 Elsevier B.V.

Original language	English
Article number	166664
Journal	Applied Surface Science
Volume	735
Online published	22 Mar 2026
DOIs	https://doi.org/10.1016/j.apsusc.2026.166664
Publication status	Online published - 22 Mar 2026

Funding

The design concept of this study employs a synergistic strategy that combines hard-phase reinforcement with solid-phase lubrication. Specifically, ZNPs and BNNSs are added to the electrolyte to achieve in-situ growth of a composite coating. Among the two additives, ZrO2 exhibits excellent chemical inertness, high hardness, fracture toughness, and thermal stability. During MAO, ZNPs are incorporated into the discharge channels and form a reinforcing second phase within the coating. They not only fill pores but also improve coating toughness and compactness via \u201Cpinning\u201D and crack-deflection mechanisms [37,38]. On the other hand, h-BN possesses a graphene-like layered structure held together by weak van der Waals forces, making it an excellent solid lubricant. Moreover, h-BN has been reported as an effective MAO additive to enhance corrosion resistance. This design aims to construct a multifunctional protective system in which ZrO2 provides structural support and wear resistance, while h-BN imparts low-friction properties. More importantly, as evidenced by the SEM and TEM results, the introduction of both nanoparticles alters the discharge behavior during MAO, promoting a \u201Cself-sealing\u201D effect and forming a denser, less porous microstructure than single-doped coatings (ZM or BM). This provides the foundation for achieving dual protection against corrosion and wear.The work was financially supported by the National Natural Science Foundation of China (Nos. 51905177 and 52105202, China), Guangdong Basic and Applied Basic Research Foundation (No. 2026A1515011007, China), Guangzhou Basic and Applied Basic Research Foundation (No. 2025A04J4575, China), Guangdong Provincial Department of Education's Characteristic Innovation Projects for Ordinary Universities (No. 2024KTSCX144, China), Research Initiation Project of Guangzhou Jiaotong University (No. K42022105, China), City University of Hong Kong Donation Research Grants (Nos. DON-RMG 9229021 and 9220061, Hong Kong), and Guangdong-Hong Kong Technology Cooperation Funding Scheme (Nos. TCFS GHP/212/22GD and CityU 9440399, Hong Kong).

Research Keywords

Corrosion
Hexagonal boron nitride
Magnesium alloy
Micro-arc oxidation
Tribo-transfer film
Zirconia

RGC Funding Information

RGC-funded

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10.1016/j.apsusc.2026.166664

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Wu, H., Guo, X., Xie, X., Xue, W., Zhu, K., Huang, M., Wu, Z., Feng, J., Xu, Z., & Chu, P. K. (2026). Dual-nanoparticle doping strategy for micro-arc oxidation coatings on magnesium alloys featuring synergistically enhanced wear and corrosion resistance. Applied Surface Science, 735, Article 166664. Advance online publication. https://doi.org/10.1016/j.apsusc.2026.166664

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title = "Dual-nanoparticle doping strategy for micro-arc oxidation coatings on magnesium alloys featuring synergistically enhanced wear and corrosion resistance",

abstract = "Improving the corrosion and wear resistance of magnesium alloys is essential for extending their service lifetime in aggressive environments. Herein, a dual-nanoparticle co-doping strategy is designed to construct dense and multifunctional micro-arc oxidation (MAO) coatings on the AZ31B magnesium alloy by introducing hexagonal boron nitride nanosheets (BNNSs) and zirconia nanoparticles (ZNPs) into the electrolyte. The incorporation of these two phases modifies the discharge behavior, promoting self-sealing and generating a compact MgO-based ceramic layer with uniformly dispersed BNNSs and ZNPs. Consequently, the ZNPs/BNNSs co-doped MAO coating (ZBM) exhibits superior barrier properties, manifested by a reduction in the corrosion current density of two orders of magnitude compared to the conventional MAO coating. Furthermore, the ZBM coating has excellent self-lubricating and anti-wear properties, including a low and stable coefficient of friction less than 0.3 and a small wear rate of 4.90 × 10-6 mm3·N−1·m−1. Surface and cross-sectional characterization of wear tracks reveal the formation of a continuous and dense tribo-transfer film on the worn surface. The exfoliated BNNSs facilitate shear sliding to provide solid lubrication, while the hard ZNPs act synergistically as load-bearing reinforcements to suppress plastic deformation and plowing. The results suggest an effective strategy to fabricate durable, low-friction, and corrosion-resistant coatings for Mg-based components. {\textcopyright} 2026 Elsevier B.V.",

keywords = "Corrosion, Hexagonal boron nitride, Magnesium alloy, Micro-arc oxidation, Tribo-transfer film, Zirconia",

author = "Hao Wu and Xinyi Guo and Xuying Xie and Weilong Xue and Kailin Zhu and Minghan Huang and Zhenghua Wu and Ji-an Feng and Zhibiao Xu and Chu, \{Paul K.\}",

year = "2026",

month = mar,

day = "22",

doi = "10.1016/j.apsusc.2026.166664",

language = "English",

volume = "735",

journal = "Applied Surface Science",

issn = "0169-4332",

publisher = "Elsevier B.V.",

}

TY - JOUR

T1 - Dual-nanoparticle doping strategy for micro-arc oxidation coatings on magnesium alloys featuring synergistically enhanced wear and corrosion resistance

AU - Wu, Hao

AU - Guo, Xinyi

AU - Xie, Xuying

AU - Xue, Weilong

AU - Zhu, Kailin

AU - Huang, Minghan

AU - Wu, Zhenghua

AU - Feng, Ji-an

AU - Xu, Zhibiao

AU - Chu, Paul K.

PY - 2026/3/22

Y1 - 2026/3/22

N2 - Improving the corrosion and wear resistance of magnesium alloys is essential for extending their service lifetime in aggressive environments. Herein, a dual-nanoparticle co-doping strategy is designed to construct dense and multifunctional micro-arc oxidation (MAO) coatings on the AZ31B magnesium alloy by introducing hexagonal boron nitride nanosheets (BNNSs) and zirconia nanoparticles (ZNPs) into the electrolyte. The incorporation of these two phases modifies the discharge behavior, promoting self-sealing and generating a compact MgO-based ceramic layer with uniformly dispersed BNNSs and ZNPs. Consequently, the ZNPs/BNNSs co-doped MAO coating (ZBM) exhibits superior barrier properties, manifested by a reduction in the corrosion current density of two orders of magnitude compared to the conventional MAO coating. Furthermore, the ZBM coating has excellent self-lubricating and anti-wear properties, including a low and stable coefficient of friction less than 0.3 and a small wear rate of 4.90 × 10-6 mm3·N−1·m−1. Surface and cross-sectional characterization of wear tracks reveal the formation of a continuous and dense tribo-transfer film on the worn surface. The exfoliated BNNSs facilitate shear sliding to provide solid lubrication, while the hard ZNPs act synergistically as load-bearing reinforcements to suppress plastic deformation and plowing. The results suggest an effective strategy to fabricate durable, low-friction, and corrosion-resistant coatings for Mg-based components. © 2026 Elsevier B.V.

AB - Improving the corrosion and wear resistance of magnesium alloys is essential for extending their service lifetime in aggressive environments. Herein, a dual-nanoparticle co-doping strategy is designed to construct dense and multifunctional micro-arc oxidation (MAO) coatings on the AZ31B magnesium alloy by introducing hexagonal boron nitride nanosheets (BNNSs) and zirconia nanoparticles (ZNPs) into the electrolyte. The incorporation of these two phases modifies the discharge behavior, promoting self-sealing and generating a compact MgO-based ceramic layer with uniformly dispersed BNNSs and ZNPs. Consequently, the ZNPs/BNNSs co-doped MAO coating (ZBM) exhibits superior barrier properties, manifested by a reduction in the corrosion current density of two orders of magnitude compared to the conventional MAO coating. Furthermore, the ZBM coating has excellent self-lubricating and anti-wear properties, including a low and stable coefficient of friction less than 0.3 and a small wear rate of 4.90 × 10-6 mm3·N−1·m−1. Surface and cross-sectional characterization of wear tracks reveal the formation of a continuous and dense tribo-transfer film on the worn surface. The exfoliated BNNSs facilitate shear sliding to provide solid lubrication, while the hard ZNPs act synergistically as load-bearing reinforcements to suppress plastic deformation and plowing. The results suggest an effective strategy to fabricate durable, low-friction, and corrosion-resistant coatings for Mg-based components. © 2026 Elsevier B.V.

KW - Corrosion

KW - Hexagonal boron nitride

KW - Magnesium alloy

KW - Micro-arc oxidation

KW - Tribo-transfer film

KW - Zirconia

UR - https://www.scopus.com/pages/publications/105034112999

UR - https://www.scopus.com/record/pubmetrics.uri?eid=2-s2.0-105034112999&origin=recordpage

U2 - 10.1016/j.apsusc.2026.166664

DO - 10.1016/j.apsusc.2026.166664

M3 - RGC 21 - Publication in refereed journal

SN - 0169-4332

VL - 735

JO - Applied Surface Science

JF - Applied Surface Science

M1 - 166664

ER -

Dual-nanoparticle doping strategy for micro-arc oxidation coatings on magnesium alloys featuring synergistically enhanced wear and corrosion resistance

Abstract

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Research Keywords

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ITF: Development of Key Technology to Attain a Novel Kind of Guided Bone Regeneration Membrane for Oral Implantology

DON_RMG: Fabrication, Characterization, and Properties of Functional Materials - RMGS

DON: Surface Modification and Fabrication of Advanced Materials

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