Effect of Cu₂P₂O₇ on the Formation of Black Micro-Arc Oxidation Coating on AZ31 Magnesium Alloy

Magnesium alloys require protective surface coatings for widespread application, with micro-arc oxidation (MAO) being a prominent technique. However, conventional MAO coatings are typically gray or light-colored, necessitating secondary treatments for specific colors like black, which complicates the process. This study aims to develop a one-step method for fabricating black MAO coatings on AZ31 magnesium alloy by introducing cupric pyrophosphate (Cu₂P₂O₇) as a colorant into a silicate-based electrolyte. As the Cu₂P₂O₇ concentration increased from 0 to 5 g/L, the coating color transitioned from grayish-white to pink, then brownish-black, achieving a uniform black appearance at 4-5 g/L. XPS and EDS analyses confirmed the incorporation of copper as CuO, identified as the primary coloring agent. XRD indicated that the phase composition remained MgO, MgSiO₃, and Mg, although the MgO content decreased. Microstructural analysis showed that an optimal concentration of 4 g/L enhanced coating compactness by thickening the dense layer and reducing pore size. However, electrochemical tests revealed that the incorporation of CuO significantly increased the corrosion current density, thereby reducing the coating's corrosion resistance compared to the unmodified coating. This work successfully demonstrates the one-step fabrication of black MAO coatings, elucidates the coloration mechanism involving CuO formation, and provides insights into the trade-off between aesthetic functionalization and corrosion performance.