Effects of Duty Cycle, Current Frequency, and Current Density on Corrosion Behavior of the Plasma Electrolytic Oxidation Coatings on 6061 Al Alloy in Artificial Seawater

In this study, the effects of duty cycle, current frequency, and current density on corrosion behavior of the plasma electrolytic oxidation (PEO) coatings on 6061 Al alloy in artificial seawater (3.5 wt pct NaCl solution) were investigated. To serve this purpose, the electrical parameters of a unipolar pulsed current were applied during the PEO process on 6061 Al alloy in alkaline silicate electrolyte with and without Al2O3 nanoparticles. The coating morphology and microstructure were characterized by the scanning electron microscopy. The corrosion behavior and electrochemical response of the specimens treated by plasma electrolytic oxidation were analyzed by the electrochemical impedance spectroscopy and the potentiodynamic polarization in artificial seawater. It was found that PEO coatings formed in the presence of Al2O3 nanoparticle had lower porosity and exhibited better corrosion behavior compared with the coatings formed in the absence of Al2O3 nanoparticle in the structure. This can be attributed to the nanoparticles' incorporation and penetration through the PEO coatings. On the other hand, the decrease in the current density and increases in the duty cycle and frequency lead to further reduction of the nanoparticles' incorporation and distribution on the coating surface.