Corrosion behavior and constant load scratch adhesion properties of CeO2 doped ceramic composite layer via micro arc oxidation on Al 1050 alloy

In this study, CeO2-doped ceramic coatings were produced on Al 1050 alloy by micro-arc oxidation (MAO) using a silicate-alkaline electrolyte containing 0, 0.5, 1, and 2% CeO2. The aim was to investigate the effect of CeO2 addition on the microstructure, phase composition, corrosion behavior, and constant-load scratch adhesion performance of the coatings. Surface characterization was carried out by SEM, EDS, XRD, and 3D profilometry, while corrosion performance was evaluated by potentiodynamic polarization and electrochemical impedance spectroscopy in 3.5 wt% NaCl solution. Scratch tests were also performed to assess the mechanical integrity of the coatings. The results showed that increasing CeO2 content improved coating uniformity, reduced surface roughness and porosity, and promoted the formation of a denser oxide structure. XRD analysis confirmed that γ-Al2O3 was the predominant alumina phase in all coatings, while Ce-containing species were incorporated into the oxide layer without forming additional detectable phases. Electrochemical results revealed that CeO2 addition significantly improved corrosion resistance by lowering the corrosion current density and increasing the polarization resistance. Scratch test results further showed improved adhesion-related behavior with reduced crack formation and surface damage. Overall, CeO2 addition effectively enhanced both the corrosion protection and mechanical performance of MAO coatings on Al 1050 alloy.