Plasma electrolytic oxidation ceramic coatings proceed by porous anodic film

Ceramic coatings were performed on aluminum through plasma electrolytic oxidation (PEO) in a Na5P3O10 solution with various concentrations of NaOH. It was revealed that the concentration of NaOH affected the types of anodic films and the activity of plasma discharges. Emphatic investigation was performed on the coatings fabricated in the electrolyte with addition of 1 g L-1 NaOH, focusing on the coating microstructure evolution and coating corrosion resistance. Some coatings were detached from the substrate, showing that the oxide particles on the anodic film C/S interface underwent profile variations from hemisphere to polygon, and its interpore distance decreased over time. The formations of pores of anodic films and plasma discharge of the PEO coatings were both easy to occur around the existing pores and the existing discharge channels. Fractured cross-section showed that a pancake-like structure corresponded to a discharge channel, a cavity, and a barrier layer protrusion whose area was similar to that of the corresponding pancake-like structure. The data of potentiodynamic polarization measurements showed that the sample treated with PEO for 10 min possessed the lowest i(corr) value of 4.97E-8 A cm(-2), the most positive E-pit value of -0.63 V, and the highest R-p value of 2.66E5 Omega cm(2). EIS data of 10 min sample exhibited the highest R-2 value of 1.61E6 Omega cm(2), demonstrating the best corrosion resistance among these samples. (C) 2019 Elsevier B.V. All rights reserved.