The correlation between the Na2SiO3·9H2O concentrations and the characteristics of plasma electrolytic oxidation ceramic coatings

Various plasma electrolytic oxidation (PEO) ceramic coatings were fabricated on aluminum in the electrolytes with different concentrations of Na2SiO3·9H2O. The morphology of fractured cross-section and coating/substrate (C/S) interface, phase compositions, and corrosion behavior of these ceramic coatings were characterized employing field emission scanning electron microscopy (SEM) equipped with energy dispersive X-ray spectroscopy (EDS), X-ray diffractometer (XRD), potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) measurements. The results showed that adding Na2SiO3·9H2O in the electrolyte could reduce the decrease amplitude of the voltage-time curve, and it can affect the types of the anodic film before the beginning of plasma discharges. A novel phenomenon was recorded as PEO treatment was carried out in the electrolyte with 1.85 g l−1 Na2SiO3·9H2O that the substrate was first covered by a barrier-type anodic film, and then a porous-type anodic film appeared after the barrier-type anodic film was broken down. The anodic film continued to grow for a long duration in the PEO process after being broken down. Characteristics of PEO ceramic coatings with a similar thickness acquired in various electrolytes were also evaluated. XRD results indicated that these ceramic coatings of similar thickness were mainly composed of α-Al2O3 and γ-Al2O3, and the α-Al2O3 proportion decreased with increasing Na2SiO3·9H2O concentration. The electrochemical data showed that the corrosion resistance of these PEO ceramic coatings of similar thickness decreased by adding Na2SiO3·9H2O in the electrolyte.