Plasma electrolytic oxidation induced ‘local over-growth’ characteristic across substrate/coating interface: Effects and tailoring strategy of individual pulse energy

Plasma electrolytic oxidation (PEO) coatings fabricated on 6061 aluminum alloy under different applied voltages (400 V, 500 V and 600 V) were used to investigate the plasma discharge induced ‘local over-growth’ characteristics across substrate/coating interface. The instant microdischarges across the local plasma channels induce the ‘micro molten pool’ products and then solidify rapidly to form ‘over-growth’ oxides region extending into substrate. A thin bonding layer composed of nanocrystalline and amorphous Al₂O₃ with a constant thickness of ~600 nm is always forming on the interface. The intact interface structure of the “local over-growth” characteristic patterns was presented perfectly by both microdischarge-sculpted substrate side ‘pits’ and electrochemically detached coating side ‘protrusions’. The patterns demonstrate that the over-growth ‘pits’ and ‘protrusions’ gradually grow up with increasing applied voltage, which is attributed to the larger discharge channels and molten pools caused by the increased size and intensity of plasma discharges. The speculative ‘over-growth’ mechanism of discharge event during plasma electrolytic oxidation process is described. This work provides insights to control ‘over-growth’ characteristics of substrate/coating interface by tailoring electrical parameters or electrolytes composition. And this strategy has a potential application to fabricate micro-nano structure or optimize outstanding performance of PEO coatings.