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<p>Diamond-Like Carbon (DLC) coatings are well known for their outstanding tribological performance and chemical inertness, making them promising surface treatments for corrosion-prone lightweight alloys. In this study, a ~ 3&#xa0;μm thick DLC coating was deposited onto an AZ31 magnesium alloy to mitigate its intrinsic susceptibility to corrosion and frictional instability. Surface characterization confirmed the formation of a dense, uniform, and carbon-rich coating with good interfacial integrity. Corrosion behavior was evaluated in simulated body fluid (SBF) at 37&#xa0;°C, where the DLC layer acted as an effective barrier against electrolyte penetration, reducing hydrogen evolution from 13.2 to 6.1 mL·cm⁻² (~ 54% reduction) after 160&#xa0;h of immersion and significantly reducing magnesium dissolution and surface degradation. Scratch adhesion tests demonstrated strong coating adhesion, with critical loads of LC₁ = 5.78 ± 0.29&#xa0;N. The frictional response was investigated using low-cycle scratch fatigue tests under a constant normal load of 2.2&#xa0;N, corresponding to an infra-LC₁ regime, i.e., below the cohesive failure load LC₁. Under these conditions, the DLC-coated surface exhibited stable frictional behavior, with only minor variations during cycling. A progressive increase in the coefficient of friction from 0.11 ± 0.05 to 0.18 ± 0.05 was observed with increasing scratch cycles (1 to 9 cycles), accompanied by a controlled evolution of the residual scratch depth from approximately 1.5–1.8&#xa0;μm to 3–3.4&#xa0;μm, indicating limited surface damage. Post-test microscopic analyses revealed localized crack initiation without evidence of catastrophic delamination. Overall, these results demonstrate that DLC coatings provide an effective and durable strategy for enhancing both corrosion resistance and frictional stability of magnesium alloys under cyclic contact loading.</p>

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Enhancing Corrosion Resistance and Frictional Behavior of Magnesium Alloys Via Diamond-like Carbon Coatings

  • 期刊论文

  • 发表日期：

    2026年5月15日

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  • Ali Beskri,
  • Mohamed Salah Atallah,
  • Kaouther Khlifi,
  • Najoua Barhoumi,
  • Masoud Atapour

摘要

Diamond-Like Carbon (DLC) coatings are well known for their outstanding tribological performance and chemical inertness, making them promising surface treatments for corrosion-prone lightweight alloys. In this study, a ~ 3 μm thick DLC coating was deposited onto an AZ31 magnesium alloy to mitigate its intrinsic susceptibility to corrosion and frictional instability. Surface characterization confirmed the formation of a dense, uniform, and carbon-rich coating with good interfacial integrity. Corrosion behavior was evaluated in simulated body fluid (SBF) at 37 °C, where the DLC layer acted as an effective barrier against electrolyte penetration, reducing hydrogen evolution from 13.2 to 6.1 mL·cm⁻² (~ 54% reduction) after 160 h of immersion and significantly reducing magnesium dissolution and surface degradation. Scratch adhesion tests demonstrated strong coating adhesion, with critical loads of LC₁ = 5.78 ± 0.29 N. The frictional response was investigated using low-cycle scratch fatigue tests under a constant normal load of 2.2 N, corresponding to an infra-LC₁ regime, i.e., below the cohesive failure load LC₁. Under these conditions, the DLC-coated surface exhibited stable frictional behavior, with only minor variations during cycling. A progressive increase in the coefficient of friction from 0.11 ± 0.05 to 0.18 ± 0.05 was observed with increasing scratch cycles (1 to 9 cycles), accompanied by a controlled evolution of the residual scratch depth from approximately 1.5–1.8 μm to 3–3.4 μm, indicating limited surface damage. Post-test microscopic analyses revealed localized crack initiation without evidence of catastrophic delamination. Overall, these results demonstrate that DLC coatings provide an effective and durable strategy for enhancing both corrosion resistance and frictional stability of magnesium alloys under cyclic contact loading.