Al coating of varying thicknesses in the 50 to 200 nm range was coated on AZ31 Mg alloys to improve its corrosion capabilities. The thermal evaporation method is used for coating AZ31 Mg alloys. GIXRD, SEM, AFM and XEDS studied the structure, microstructure, and chemical analysis. GIXRD studies showed an amorphous thin film on the surface. AFM showed that the surface roughness increases with the coating thickness. Corrosion studies were done by electrochemical analysis in 3.5 wt-% NaCl environment. The Al coating has improved the corrosion resistance of the AZ31 alloy to the best with the lowest corrosion rate 0.07 mmpy, with the corrosion current density and corrosion potential of 0.32 × 10−5 A/cm2 and −1.17 V, respectively.
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