One-step Zn-based composites fabrication via double glow plasma for synergistic mechanical-corrosion control and interface mechanism elucidation

ZH Fan and ZQ Huang and XY Tao and QH Li and YQ Pan and YF Tan and WJ Lin and WP Liu and HY Wu, JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY- JMR&T, 39, 3475-3487 (2025).

DOI: 10.1016/j.jmrt.2025.09.224

In this work, a one-step double glow plasma surface alloying(DGPSA) technique was employed to fabricate Znbased composites reinforced with columnar iron phases, enabling controllable degradation rates. The composite features a surface-covered Ta transition layer with a content of up to 66 wt%, while the sintered interior demonstrates strong bonding between the Zn matrix and iron reinforcement. Experimental results revealed that the Zn-8Fe composite achieves a compressive yield strength (CYS) of 401 MPa and an elastic modulus increased to 7581 MPa. Immersion tests further demonstrated that the sample with a 40 wt% Ta coating exhibits a corrosion weight loss rate of only 6.5 x 10-4 g cm-2 & sdot;day-1, representing a 36.1 % reduction compared to pure Zn (1.02 x 10-3 g cm-2 & sdot;day-1). Molecular dynamics simulations elucidate the sintering mechanism at the Zn-Fe interface. The Zn matrix, characterized by its high thermal expansion coefficient, effectively fills the initial interfacial gaps during thermal cycling. The iron reinforcement exhibits a high thermal conductivity of 4.62 x 10-2 W/(m & sdot;K), which further enhances interfacial bonding, achieving a pull-out strength of up to 2.40 x 10-7 N. This study provided both experimental and theoretical support for the design of biodegradable Zn-based implant materials, offering a breakthrough strategy for biomedical applications of Zn alloys.

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