Porosity in plasma electrolytic oxide coatings

Plasma electrolytic oxide coatings are generally assumed to be almost fully dense. However, evidence is presented here for the presence of sub-micrometre, surface-connected porosity in such coatings, on aluminium alloys, at levels of the order of 20%. This evidence comes from densitometry, mercury porosimetry, helium pycnometry, BET adsorption measurements and high-resolution scanning electron microscopy. The very fine scale of the porosity (pore diameter similar to 10 to 100 nm), coupled with severe difficulties in making unambiguous microstructural observations, may account for the failure to detect this feature previously. It is pointed out that various measured properties, such as Young's modulus and thermal conductivity, are consistent with the presence of these relatively high porosity levels. Various other observed characteristics can also be explained on this basis. Finally, a possible mechanistic origin for the porosity is proposed. (c) 2006 Published by Elsevier Ltd on behalf of Acta Materialia Inc.