Particle Size Influences on the Coating Microstructure through Green Chromia Inclusion in Plasma Electrolytic...

In an effort to color the aluminum alloy surface green via plasma electrolytic oxidation (PEO), two alkaline solutions have been employed with particulate inclusions and sodium aluminate. Electrolyte I comprises a self-made chromia pigment with a mean particle size 69 nm, whereas electrolyte II contains a commercially available pigment, GN-M, with a larger particle size 351 nm. Both pigments are oxygen deficient Cr₂O_3-δ of corundum-type structure before coating, the oxidative environment of PEO converts them into stoichiometric Cr₂O₃. In electrolyte I and II, the oxides of chromium and aluminum deposit simultaneously under analogous PEO conditions, yet resulting in very different microstructures. The GN-M inclusion of large size amasses on top of the coating, while the self-made inclusion goes deep, and closely associates with alumina and pores. The oxide coating, grown in electrolyte II, consists of a top Cr₂O₃-rich layer and a dense alumina layer underneath, delineated by the boundary marked with microdischarge burns. On the other hand, the self-made particulate inclusion appears to bring the electric microdischarges inside the coating and create inner pores and damages. The structure difference, caused by the difference in microdischarge locations, is attributed to shifting of the Cr₂O₃-Al₂O₃ interface where p-type and n-type semiconductors meet.