Microstructural characteristic, outward-inward growth behavior and formation mechanism of MAO ceramic coating on the surface of ADC12 Al alloy with micro-groove

The ceramic coatings on the surface of aluminum alloy substrates with micro-grooves have been successfully fabricated in the silicate solution via micro-arc oxidation (MAO) approach. Microstructure characterization showed that the larger main discharge channels were located in the center of micro-groove, the smaller secondary discharge channels were located on both sides of main discharge channel; and a few irregular micro-pores existed in the vicinity of all discharge channels, which were mainly cause by the rapid cooling and solidification of discharge channels hindering the removal of gases produced via reaction. Moreover, the growing direction of coating in the initial stage was mainly outward-growth and resulted in the formation of inverted triangle coating structure, which was due to the sharp-angled effect. But in the final growing stage, the inward-growth behavior played a key role owing to the spark transfer. According to above results and discussion, the formation of smooth, uniform and homogeneous ceramic coating on the surface of whole trapezoidal micro-groove substrate contained four stages: anodic oxidation growth, sharp corner rapid growth, coating homogenization and groove self-filling.