Incorporation mechanism of colloidal TiO2 nanoparticles and their effect on properties of coatings grown on 7075 Al alloy from silicate-based solution using plasma electrolytic oxidation

Plasma electrolytic oxidation (PEO) was applied using a pulsed unipolar waveform to produce Al2O3-TiO2 composite coatings from sol electrolytic solutions containing colloidal TiO2 nanoparticles. The sol solutions were produced by dissolving 1, 3, and 5 g/L of potassium titanyl oxalate (PTO) in a silicate solution. Scanning electron microscopy, energy dispersive spectrometry, X-ray diffraction, and Raman spectroscopy were applied to characterizing the coatings. Corrosion behavior of the coatings was investigated using polarization and impedance techniques. The results indicated that TiO2 enters the coating through all types of micro-discharging and is doped into the alumina phase. The higher level of TiO2 incorporation results in the decrease of surface micro-pores, while the lower incorporation shows a reverse effect. It was revealed that the higher TiO2 content makes a more compact outer layer and increases the inner layer thickness of the coating. Electrochemical measurements revealed that the coating obtained from the solution containing 3 g/L PTO exhibits higher corrosion performance than that obtained in the absence of PTO. The coating produced in the absence of PTO consists of gamma-Al2O3, delta-Al2O3 and amorphous phases, while alpha-Al2O3 is promoted by the presence of PTO.