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<p>Magnesium (Mg) alloys hold immense potential for applications in aerospace, defense, and medical devices. However, their use is hindered by notably poor corrosion resistance. In this study, ultrasonic burnishing (UB) is proposed as a way control surface corrosion of Mg alloys (here, AZ91D series). The results show that UB processing decreases surface roughness, advantageously increases compressive residual stress, and refines grain sizes, and these benefits outcompete turning and polishing for surface modification. With this, the corrosion rates of the UB-processed AZ91D are reduced in both the standard 3.5 wt.% NaCl and simulated body fluid (SBF) solutions. With this fundamental understanding between corrosion and surface processing outcomes by UB, we have extended our learning to AZ91D corrosion control in SBF environment for an industry-required corrosion rate. Reverse surface engineering is performed to optimize UB parameters and break the corrosion limits in AZ91D, achieving a corrosion rate of &lt; 0.1&#xa0;mm/year in SBF and approving its biodegradable implant applications.</p>

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Electrochemistry-Informed Surface Engineering by Ultrasonic Burnishing for Improved Corrosion Resistance in AZ91D Mg Alloy

  • 期刊论文

  • 发表日期：

    2026年3月18日

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  • Xuehui Shen,
  • Shiqi Ma,
  • Shiru He,
  • Yalong Shi,
  • Nan Xu,
  • Shuaihang Pan

摘要

Magnesium (Mg) alloys hold immense potential for applications in aerospace, defense, and medical devices. However, their use is hindered by notably poor corrosion resistance. In this study, ultrasonic burnishing (UB) is proposed as a way control surface corrosion of Mg alloys (here, AZ91D series). The results show that UB processing decreases surface roughness, advantageously increases compressive residual stress, and refines grain sizes, and these benefits outcompete turning and polishing for surface modification. With this, the corrosion rates of the UB-processed AZ91D are reduced in both the standard 3.5 wt.% NaCl and simulated body fluid (SBF) solutions. With this fundamental understanding between corrosion and surface processing outcomes by UB, we have extended our learning to AZ91D corrosion control in SBF environment for an industry-required corrosion rate. Reverse surface engineering is performed to optimize UB parameters and break the corrosion limits in AZ91D, achieving a corrosion rate of < 0.1 mm/year in SBF and approving its biodegradable implant applications.