The microstructure and properties of the composite TiN-Ti-Al type titanium nitride surface layer with a sub-layer of titanium and aluminium produced on AZ91D magnesium alloy using a hybrid PVD method including final sealing by hydrothermal treatment were investigated. The results were analysed in terms of the microstructure-properties correlation, to approach the role of the sub-layers and the mechanisms involved in the properties improvement. The microstructure investigations indicate that the composite titanium nitride layers are tight and have nano-crystalline, diffusive character and multi zone microstructure of the type TixOy-TiN-Ti-Al-Al3Mg2-Al12Mg12. The significant corrosion resistance improvement of the AZ91D alloy obtained using the sealed composite titanium nitride layers was found to be the result of a synergistic mechanism which combined hydrothermal treatment of the layer with an action of aluminium sub-layer which is critical to make the sealing effective. The diffusive bonding via Mg-Al zone improves adhesion and the load bearing capacity of titanium nitride layers in wear conditions. (C) 2015 Elsevier B.V. All rights reserved.