Highly Corrosion-Resistant Mg Alloys through Tailored Alloying and Processing

Magnesium (Mg) alloys offer a high strength-to-weight ratio, but their applications are limited by poor corrosion resistance and modest mechanical properties. Here, we present an Mg alloy containing Ca, Ti, Zn, and In. The synergistic influence of these alloying elements results in high corrosion resistance through the formation of a stable surface film. The alloy was synthesized via high-energy ball milling of elemental powders, followed by spark plasma sintering. X-ray diffraction and scanning electron microscopy revealed a homogeneous Mg-rich matrix containing finely dispersed intermetallic phases. Electrochemical measurements in aqueous chloride solutions showed a low corrosion current density, a relatively noble corrosion potential, and a passive-like region, demonstrating significantly improved corrosion resistance compared to conventional Mg alloys. These results suggest that synergistic alloying with Ca, Ti, Zn, and In, combined with non-equilibrium processing routes, is a promising pathway to develop lightweight Mg alloys with enhanced corrosion resistance and mechanical performance.