Magnesium alloy is a potential biomedical implant because of its outstanding biodegradability and mechanical properties. But the poor corrosion resistance of AZ91 magnesium alloy in physiological solution limits its biomedical applications. In order to improve the corrosion resistance and biological performance of AZ91 magnesium alloy, we have fabricated a strontium-substituted porous hydroxyapatite (Sr-HAP)/zinc oxide (ZnO) duplex layer on AZ91 magnesium alloy by electrodeposition. The porous Sr-HAP/ZnO duplex-layer coating on AZ91 magnesium alloy was characterized by Fourier transform infrared spectroscopy, X-ray diffraction, high-resolution scanning electron microscopy and energy dispersive X-ray analysis. Also, the mechanical properties of the duplex-layer coating were evaluated using adhesion and Vickers micro-hardness tests. The effects of the duplex-layer coating on the corrosion behavior of AZ91 magnesium alloy were also investigated in simulated body fluid using electrochemical studies. The potentiodynamic polarization and electrochemical impedance spectroscopy results indicated that the corrosion resistance of AZ91 magnesium alloy was significantly improved by the duplex-layer coating. The in vitro cell-material interaction of the duplex-layer coating was observed with human osteosarcoma MG63 cells for cell viability at 1, 4 and 7 days of incubation and the coating exhibited good biocompatibility. Hence, from the obtained results we believe that the duplex-layer made of ZnO together with porous Sr-HAP on AZ91 magnesium alloy could provide effective corrosion protection and enhanced bioactivity. Thus, duplex-layer-coated AZ91 magnesium alloy can serve as a promising candidate for orthopedic applications.
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