Growth kinetics and morphology of plasma electrolytic oxidation coating on aluminum

Plasma electrolytic oxidation (PEO) was carried out on AA1190 aluminum alloy in mixed silicate-phosphate-based electrolyte in order to fabricate ceramic coating under constant current density. The variations of PEO coating duration with kinetics, surface roughness, amount and size of discharge channels were studied with respect to PEO processing time. The growth mechanism of the ceramic coating was described considering a variation of volume and diameters of discharge channels and pancakes during the PEO. Scanning electron microscope (SEM), atomic force microscope (AFM), and roughness tester were used to study the plasma discharge channels of the PEO coatings. In addition, the effect of alumina nanoparticles in the electrolyte as the suspension was studied on the geometric parameters of discharge channels. It seems that the nanoparticles are adsorbed to the locations of erupted molten oxide, where the dielectric breakdown occurs. Nanoparticles were embedded in the dense oxide layer and were adsorbed at the walls of voids and coatings surface. As a result, they caused significant changes in roughness parameters of the samples containing nanoparticles compared to those without nanoparticles. The obtained results showed that growth kinetics followed a linear trend with respect to PEO coating duration. It was also observed that in the absence of alumina nanoparticles, the average volume of the pancakes is 150% greater than the ones fabricated in the suspension of nanoparticles. Besides, increasing the PEO coating duration leads to adsorbing more nanoparticles on the coating surface, filling the voids, and flattening the surface, and alterations in Rv, Rsk, and Rlo parameters. Correlation between the diameter of discharge channel (dc) and thickness of the pancake (h) also showed a linear relation.