Nature of the growth of plasma electrolyte oxidation coating on Aluminum

The localized dielectric breakdown had been considered as the driving force for growth of plasma electrolytic oxide (PEO) coatings for several decades. However, the TEM study here reveals the dielectric breakdown behavior has little contribution for coating thickening. The presented evidences show the nature of PEO coating growth in all three consecutive stages I-III is ionic migration behavior inside the amorphous alumina layer (AAL) at the coating/matrix interface. The evolution of morphological characterizations in the PEO process is attributed to the interfacial reactions of AAL/alkaline (stage I), AAL/discharge-on-surface (stage II) and AAL/discharge-in-pore (stage III).