Influence of Concentrations of KOH and Na2SiO3 Electrolytes on the Electrochemical Behavior of Ceramic Coatings on 6061 Al Alloy Processed by Plasma Electrolytic Oxidation

doi:10.1007/s40195-016-0384-3

Abstract

Abstract:

In this study, ceramic coatings were deposited on 6061 Al alloy using a plasma electrolytic oxidation (PEO) technique, and the effect of concentrations of KOH and Na₂SiO₃ as electrolytes for PEO process was studied on microstructure, chemical composition, and electrochemical behavior of PEO coatings formed on the 6061 Al alloy. The results indicated that the increase in concentration of KOH led to rise in electrical conductivity of electrolyte. Consequently, the breakdown voltage reduced, which in turn improved the surface quality and the corrosion behavior. Moreover, the increase in concentration of Na₂SiO₃ resulted in the increase in incorporation of Si in the coating, which led to a higher corrosion potential in the concentration of 4 g L^-1. According to this investigation, the best protection behavior of coatings can be obtained when the KOH and Na₂SiO₃ concentrations in PEO electrolyte are equal to 4 g L^-1.

Key words: Al alloy, Plasma electrolytic oxidation (PEO), Potentiodynamic polarization, Electrochemical impedance spectroscopy (EIS)

Arash Fattah-Alhosseini, Mojtaba Vakili-Azghandi, Mohsen K. Keshavarz. Influence of Concentrations of KOH and Na₂SiO₃ Electrolytes on the Electrochemical Behavior of Ceramic Coatings on 6061 Al Alloy Processed by Plasma Electrolytic Oxidation[J]. Acta Metallurgica Sinica (English Letters), 2016, 29(3): 274-281.

Figures/Tables 10

Table 1 Different chemistry conditions of electrolytes used for PEO coating process of 6061 Al alloy samples

Samples	S1	S2	S3	S4	S5
KOH (g L^-1)	2	3	4	4	4
Na₂SiO₃ (g L^-1)	2	2	2	3	4

Fig. 1 Time versus voltage curves of PEO-treated 6061 Al alloy samples at different concentrations of KOH and Na2SiO3

Fig. 2 Potentiodynamic polarization curves of PEO-coated 6061 Al alloy in different concentrations of KOH and Na2SiO3

Fig. 3 Variations in the corrosion current density a, passive corrosion density b, and corrosion potential c of 6061 Al alloy with and without PEO coatings

Fig. 4 Bode a and Bode-phase b plots of PEO-coated 6061 Al alloy in different concentrations of KOH and Na2SiO3

Fig. 5 Equivalent electrical circuits used to fit the impedance data of 6061 Al alloy with and without PEO coatings

Fig. 6 Variations in the corrosion resistance of functional layer a, corrosion resistance of barrier b, capacitance of functional layer c, and capacitance of barrier layer d of 6061 Al alloy with and without PEO coatings

Fig. 7 SEM micrographs of cross sections and surfaces of coatings of samples S1, S2, S3, S4, and S5, respectively

Fig. 8 XRD patterns of 6061 Al alloy, sample S3, and sample S5

Fig. 9 SEM micrographs of surfaces of 6061 Al alloy a, and sample S5 b after 600-h immersion in 3.5 wt% NaCl solution

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Influence of Concentrations of KOH and Na₂SiO₃ Electrolytes on the Electrochemical Behavior of Ceramic Coatings on 6061 Al Alloy Processed by Plasma Electrolytic Oxidation

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