Effects of advanced forming and processing techniques on corrosion behavior of magnesium alloys: A review

doi:10.1016/j.metadv.2026.02.026

Abstract

Abstract:

Magnesium (Mg) alloys, featuring low density, high specific strength, and favorable biocompatibility, face limitations in applications due to their poor corrosion resistance. Forming and processing techniques can affect the corrosion behavior of Mg alloys by regulating microstructural characteristics, such as grain size, second phases, texture, dislocation density, and surface properties, etc. Therefore, recent studies on the corrosion properties of Mg alloys prepared by advanced forming and processing techniques should be reviewed. In this review, the effects of special casting, additive manufacturing, severe plastic deformation, and surface physical modification techniques on corrosion behaviors of Mg alloys are discussed. The underlying corrosion mechanisms are systematically analyzed, and suggestions for future research avenues are proposed.

Key words: Magnesium, Corrosion behavior, Forming technique, Processing technique

Zi-Lin Li, Nuo Xu, Zhang-Zhi Shi, Lu-Ning Wang. Effects of advanced forming and processing techniques on corrosion behavior of magnesium alloys: A review[J]. Metals Advances, 2026, 46: 17-33.

Figures/Tables 16

Fig. 1. Degradation products formed during Mg alloy corrosion and the corresponding chemical reactions [19].

Fig. 2. Schematic illustration of the rheocasting (RC), squeeze casting (SC), centrifugal casting (CC), directional solidification (DS), and high-pressure die casting (HPDC) process [26], [27], [28], [29], [30].

Fig. 3. BSE pictures of AZ91 alloys with thickness: (a) 2.5 mm, (b) 4 mm, (c) 6 mm, and (d) 10 mm [31].

Fig. 4. Microstructures of Mg-4Zn alloy: (a, b) equiaxed dendritic, (c, d) cellular, (e, f) columnar dendritic [41].

Fig. 5. Schematic illustration of the laser powder bed fusion (LPBF), wire arc additive manufacturing (WAAM), friction stir additive manufacturing (FSAM), additive friction stir deposition (AFSD), and binder jetting additive manufacturing (BJAM) process [50], [51], [52], [53], [54].

Fig. 6. (a) Immersion pictures of XY and XZ surfaces soaking in SBF, (b) and (c) corrosion morphologies after immersion for 12 h, 1 d, and 7 d, respectively [55].

Fig. 7. Corroded cross-sectional morphology after 24 h immersion in 0.5% NaCl solution: (a, b) ND, (c, d) BD, (e, f) TD [60].

Fig. 8. Inverse pole figure (IPF) and Kernel average misorientation (KAM) maps of the P-WAAM formed Mg-Gd-Y-Zr alloy: (a, b) as-built; (c, d) heat-treatment [63].

Fig. 9. SEM images of LAZ931 alloy: (a) base material, (b) refined grain area, (c) left and right interface, (d) upper and lower interface [52].

Fig. 10. Macrographs of the AZ91 alloys at different states after immersion in 3.5 wt% NaCl solution for 7 d (corrosion products removed) [75].

Fig. 11. Schematic illustration of the accumulative roll bonding (ARB), equal-channel angular pressing (ECAP), high-ratio differential speed rolling (HRDSR), high-pressure torsion (HPT), spiral rolling (SR), and multi directional forging (MDF) process [76], [78], [79], [80], [81], [82].

Fig. 12. EDS line-scan results obtained from the cross-sectional (left column) and top (right column) views after immersion in PBS [94].

Fig. 13. Schematic illustration of the laser shock peening (LSP), surface mechanical attrition treatment (SMAT), laser surface modification (LSM), ultrasonic nanocrystal surface modification (UNSM), and friction stir processing (FSP) process [103], [104], [105], [106], [107].

Table 1. CRs of some samples in the literature (Pw stands for CR calculated by weight loss, PH stands for CR calculated by hydrogen evolution).

Sample	Technique	Medium	CR (mm/y)	Method	Ref.
AM60	HPDC	3.5% NaCl	1.43	P_w	[32]
AM60	GC	3.5% NaCl	17.63	P_w	[32]
AZ80M	As-received	3.5% NaCl	22.2	P_w	[118]
AZ80M	USP	3.5% NaCl	51.4	P_w	[118]
AZ91	Cast	3.5% NaCl	1.86	P_w	[75]
AZ91	ECAP	3.5% NaCl	0.62	P_w	[75]
Mg-3.71Zn-2.04Al-0.63Ca-0.62Mn	SR (220 ℃)	3.5% NaCl	4.99	P_w	[98]
Mg-3.71Zn-2.04Al-0.63Ca-0.62Mn	SR (300 ℃)	3.5% NaCl	2.6	P_w	[98]
Mg-3.71Zn-2.04Al-0.63Ca-0.62Mn	SR (340 ℃)	3.5% NaCl	5.52	P_w	[98]
Mg-0.59Ca-0.52Mn	MDF (300 ℃)	3.5% NaCl	0.55	P_w	[95]
Mg-0.59Ca-0.52Mn	MDF (260 ℃)	3.5% NaCl	0.81	P_w	[95]
Mg-0.59Ca-0.52Mn	MDF (220 ℃)	3.5% NaCl	0.88	P_w	[95]
Mg-0.59Ca-0.52Mn	EX	3.5% NaCl	1.15	P_w	[95]
Mg-3.68Zn-1.74Al-0.65Ca-0.46Mn	EX+MDF (180 ℃)	3.5% NaCl	1.56	P_w	[96]
Mg-3.68Zn-1.74Al-0.65Ca-0.46Mn	EX+MDF (300 ℃)	3.5% NaCl	1.13	P_w	[96]
AZ31	HPT	Hank’s	0.022	P_H	[84]
AZ91	HPT	Hank’s	0.019	P_H	[84]
CP-Mg	HPT	Hank’s	0.034	P_H	[84]
Mg-3Zn-0.2Ca-xMgO	SR	Hank’s	0.88	P_w	[81]
Mg-4.71Zn-0.6Ca	Cast	Hank’s	0.83	P_w	[119]
Mg-4.71Zn-0.6Ca	ECAP	Hank’s	0.597	P_w	[119]
Pure Mg	LPBF	Hank’s	2.5	P_w	[45]
Pure Mg	LPBF	Hank’s	33	P_w	[45]
Pure Mg	Cast	Hank’s	11	P_H	[83]
Pure Mg	HR	Hank’s	0.4	P_H	[83]
Pure Mg	ECAP	Hank’s	0.4	P_H	[83]
Pure Mg	HPT	Hank’s	0.4	P_H	[83]
WE43(1.98Nd-0.39Zr)	LPBF	Hank’s	339.83	P_H	[48]
WE43(2.23Nd-0.37Zr)	LPBF	Hank’s	49.3	P_H	[48]
WE43(2.28Nd-0.07Zr)	LPBF	Hank’s	276.35	P_H	[48]
WE43(2.45Nd-0.40Zr)	LPBF	Hank’s	23.56	P_H	[48]
WE43	GC	Hank’s	1.4	P_w	[39]
WE43	SC	Hank’s	0.6	P_w	[39]
ZK60	HPT	Hank’s	0.036	P_H	[84]
Mg-0.5Zn-0.3Ca	SLM	SBF	1.6	P_H	[117]
Mg-0.6Ca	SLM	SBF	1	P_H	[117]
Mg-2Zn-0.22Ca	Cast	SBF	10.17	P_H	[87]
Mg-2Zn-0.22Ca	HPT	SBF	6.45	P_H	[87]
Mg-2Zn-0.22Ca	ST+HPT	SBF	4.39	P_H	[87]
ZK60	LAM	SBF	2.01	P_H	[47]
ZK60	PM	SBF	8.35	P_H	[47]

Table 1. CRs of some samples in the literature (Pw stands for CR calculated by weight loss, PH stands for CR calculated by hydrogen evolution).

Sample	Technique	Medium	CR (mm/y)	Method	Ref.
AM60	HPDC	3.5% NaCl	1.43	P_w	[32]
AM60	GC	3.5% NaCl	17.63	P_w	[32]
AZ80M	As-received	3.5% NaCl	22.2	P_w	[118]
AZ80M	USP	3.5% NaCl	51.4	P_w	[118]
AZ91	Cast	3.5% NaCl	1.86	P_w	[75]
AZ91	ECAP	3.5% NaCl	0.62	P_w	[75]
Mg-3.71Zn-2.04Al-0.63Ca-0.62Mn	SR (220 ℃)	3.5% NaCl	4.99	P_w	[98]
Mg-3.71Zn-2.04Al-0.63Ca-0.62Mn	SR (300 ℃)	3.5% NaCl	2.6	P_w	[98]
Mg-3.71Zn-2.04Al-0.63Ca-0.62Mn	SR (340 ℃)	3.5% NaCl	5.52	P_w	[98]
Mg-0.59Ca-0.52Mn	MDF (300 ℃)	3.5% NaCl	0.55	P_w	[95]
Mg-0.59Ca-0.52Mn	MDF (260 ℃)	3.5% NaCl	0.81	P_w	[95]
Mg-0.59Ca-0.52Mn	MDF (220 ℃)	3.5% NaCl	0.88	P_w	[95]
Mg-0.59Ca-0.52Mn	EX	3.5% NaCl	1.15	P_w	[95]
Mg-3.68Zn-1.74Al-0.65Ca-0.46Mn	EX+MDF (180 ℃)	3.5% NaCl	1.56	P_w	[96]
Mg-3.68Zn-1.74Al-0.65Ca-0.46Mn	EX+MDF (300 ℃)	3.5% NaCl	1.13	P_w	[96]
AZ31	HPT	Hank’s	0.022	P_H	[84]
AZ91	HPT	Hank’s	0.019	P_H	[84]
CP-Mg	HPT	Hank’s	0.034	P_H	[84]
Mg-3Zn-0.2Ca-xMgO	SR	Hank’s	0.88	P_w	[81]
Mg-4.71Zn-0.6Ca	Cast	Hank’s	0.83	P_w	[119]
Mg-4.71Zn-0.6Ca	ECAP	Hank’s	0.597	P_w	[119]
Pure Mg	LPBF	Hank’s	2.5	P_w	[45]
Pure Mg	LPBF	Hank’s	33	P_w	[45]
Pure Mg	Cast	Hank’s	11	P_H	[83]
Pure Mg	HR	Hank’s	0.4	P_H	[83]
Pure Mg	ECAP	Hank’s	0.4	P_H	[83]
Pure Mg	HPT	Hank’s	0.4	P_H	[83]
WE43(1.98Nd-0.39Zr)	LPBF	Hank’s	339.83	P_H	[48]
WE43(2.23Nd-0.37Zr)	LPBF	Hank’s	49.3	P_H	[48]
WE43(2.28Nd-0.07Zr)	LPBF	Hank’s	276.35	P_H	[48]
WE43(2.45Nd-0.40Zr)	LPBF	Hank’s	23.56	P_H	[48]
WE43	GC	Hank’s	1.4	P_w	[39]
WE43	SC	Hank’s	0.6	P_w	[39]
ZK60	HPT	Hank’s	0.036	P_H	[84]
Mg-0.5Zn-0.3Ca	SLM	SBF	1.6	P_H	[117]
Mg-0.6Ca	SLM	SBF	1	P_H	[117]
Mg-2Zn-0.22Ca	Cast	SBF	10.17	P_H	[87]
Mg-2Zn-0.22Ca	HPT	SBF	6.45	P_H	[87]
Mg-2Zn-0.22Ca	ST+HPT	SBF	4.39	P_H	[87]
ZK60	LAM	SBF	2.01	P_H	[47]
ZK60	PM	SBF	8.35	P_H	[47]

Fig. 14. Schematic illustration of the role of Mg17Al12 and Mg2Ca phases in the Mg matrix where their distribution is continuous or discontinuous [122].

Fig. 15. CRs of Mg alloys subjected to SPD processes [16].

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