In situ fabrication of blue ceramic coatings on wrought Al Alloy 2024 by plasma electrolytic oxidation

Wang, Zhijiang; Nie, Xueyuan; Hu, Henry; Hussein, Riyad O.

doi:doi:10.1116/1.3675610

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Journal of Vacuum Science & Technology A / Volume 30 / Issue 2 / Plasma Science and Technology

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J. Vac. Sci. Technol. A 30, 021302 (2012); http://dx.doi.org/10.1116/1.3675610 (7 pages)

In situ fabrication of blue ceramic coatings on wrought Al Alloy 2024 by plasma electrolytic oxidation

Zhijiang Wang, Xueyuan Nie, Henry Hu, and Riyad O. Hussein

Department of Mechanical, Automotive and Materials Engineering, University of Windsor, Windsor, Ontario N9B 3P4, Canada.

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(Published online 12 January 2012)

Abstract

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In situ formation of ceramic coatings on 2024 Al alloy with a blue color was successfully achieved using a plasma electrolytic oxidation process working at atmospheric pressure. This novel blue ceramic coating overcomes the shortcomings of surface treatments resulting from conventional dyeing processes by depositing organic dyes into the porous structure of anodic film, which has poor resistance to abrasion and rapid fading when exposed to sunlight. X-ray diffraction, scanning electron microscopy, and energy dispersive spectroscopy were employed to characterize the microstructure of the blue ceramic coating. The fabricated ceramic coating was composed of CoAl₂O₄, α-Al₂O₃, and γ-Al₂O_3. By controlling the working parameters, the distribution of the CoAl₂O₄ phase on the surface can be adjusted, and plays a key role in the appearance of the coating. Electrochemical testing, thermal cycling method, and pin-on-disk sliding wear testing were employed to evaluate corrosion, thermal cycling, and wear resistance of the ceramic coatings. The results indicate that the blue ceramic coating has a similar polarization resistance to that of conventional anodic film and can significantly enhance the corrosion resistance of aluminum alloy. There are no destructive horizontal cracks observed within the blue ceramic coating when subjected to 120 times of thermal cycling, which heats the samples up to 573 K and followed by submersion in water at room temperature for 10 min. Compared with the aluminum substrate as well as a conventional anodic film coated aluminum sample, the wear resistance of the blue ceramic coating coated sample was significantly increased while the coefficient of friction was decreased from 0.34 to 0.14.

ACKNOWLEDGMENTS

This research was supported by the Natural Science and Engineering Research Council of Canada (NSERC) and the University of Windsor.

Article Outline

INTRODUCTION
EXPERIMENT
1. PEO coating preparation
2. Anodic film preparation
3. Characterization of the coating
RESULTS AND DISCUSSION
1. Microstructure of the blue ceramic coating
2. Color control of the blue ceramic coating
3. Corrosion property of the blue ceramic coating
4. Thermal cycling property of the blue ceramic coating
5. Wear resistance of the blue ceramic coating
CONCLUSIONS

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KEYWORDS and PACS

Keywords

aluminium compounds, ceramics, cobalt compounds, corrosion protective coatings, corrosion resistance, cracks, crystal microstructure, electrochemical analysis, heat treatment, oxidation, plasma deposited coatings, scanning electron microscopy, sliding friction, thin films, wear resistant coatings, wear testing, X-ray chemical analysis, X-ray diffraction

PACS

81.65.Kn

Corrosion protection
81.65.Mq

Oxidation
82.80.Ej

X-ray, Mössbauer, and other γ-ray spectroscopic analysis methods
82.80.Fk

Electrochemical methods
62.20.Qp

Friction, tribology, and hardness
81.40.Pq

Friction, lubrication, and wear

History

Received 2 August 2011
Accepted 13 December 2011
Published online 12 January 2012

Digital Object Identifier

http://dx.doi.org/10.1116/1.3675610

PUBLICATION DATA

ISSN

0734-2101 (print)

1520-8559 (online)

Publisher

American Vacuum Society

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