Development of Nano-SiO₂ blended polyetherimide coating through electrospinning for improved corrosion resistance of AZ91D magnesium alloy

Magnesium alloys—particularly those of the AZ91D are widely known for having high specific strength and low density, but their significant corrosion propensity limits their application in essential sectors. Many studies have been done to increase the AZ91D alloy's resistance to corrosion, and it has already been shown that an electro-spun polymeric coating provides better protection. The protective barrier was then created by combining nano-SiO₂ particles with polyetherimide (PEI) and entirely using their anti-corrosive qualities. While the polymer concentration and electrospinning procedure have been optimized previously in the literature, this work aims to improve corrosion protection by optimizing the nanoparticle content. Optical Microscopy (OM), Atomic force microscopy (AFM), combined with EDAX and scanning electron microscopy (SEM), were utilized to analyze the coating thickness, surface morphology and coating uniformity. Potentiodynamic polarization and corroded sample analysis assessed the coatings' efficacy. The findings showed that, if the right composition is obtained, nano-ceramic content significantly improves corrosion resistance for AZ91D, resulting in a denser and flawless coating. In light of this, this work may help researchers create more sophisticated, environmentally friendly corrosion protection systems for magnesium alloys, which companies looking for low-weight and corrosion-resistant materials.