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This paper aims to achieve phosphating via optimal features of Mg metal as a suitable base coating, which is considered for other properties such as barrier properties against the passage of several factors.

In this research, in the phosphate bath, immersion time, temperature and the content of sodium nitrite as an accelerator were changed.

As a result, increasing the immersion time of AZ31 Mg alloy samples in the phosphating bath as well as increasing the ratio of sodium dodecyl sulfate (SDS) concentration to sodium nitrite concentration in the phosphating bath formulation increase the mass of phosphating formed per unit area of the Mg alloy. The results of the scanning electron microscope test showed phosphating is not completely formed in short immersion times, which is a thin and uneven layer.

Mg and its alloys are sensitive to galvanic corrosion, which would lead to generating several holes in the metal. As such, it causes a decrease in mechanical stability as well as an unfavorable appearance.

Mg is used in several industries such as automobile and computer parts, mobile phones, astronaut compounds, sports goods and home appliances.

Nevertheless, Mg has high chemical reactivity, so an oxide-hydroxide layer is formed on its surface, which has a harmful effect on the adhesion and uniformity of the coating applied on Mg.

By increasing the ratio of SDS concentration to sodium nitrite concentration in the phosphating bath, the corrosion resistance of the phosphating increases.

This study aims to investigate the role of aluminium (Al) in marine environment and the corrosion mechanism of galvalume coatings by conducting accelerated experiments and data analysis.

Samples were subjected to accelerated corrosion for 136 days via salt spray tests to simulate the natural conditions of marine environment and consequently accelerate the experiments. Subsequently, the samples were examined using various test methods, such as EDS, scanning electron microscopy (SEM), X-ray diffraction (XRD) and electrochemical impedance spectroscopy (EIS), and the obtained data were analysed.

Galvalume coatings comprised interdigitated zinc (Zn)-rich and dendritic Al-rich phases. Corrosion was observed to begin with a Zn-rich phase. The primary components of the corrosion product film were Al₂O₃ and Zn₅(OH)₈Cl₂·H₂O. It was confirmed that the role of Al was to form a dense protective film, thereby successfully blocking the entry of corrosive media and protecting the iron substrate.

This study provides a clearer understanding of the corrosion mechanism and kinetics of galvalume coatings in a simulated marine environment. In addition, the role of Al, which is rarely mentioned in the literature, was investigated.