Nucleation and growth behavior of coating film on Mg–Al–Zn alloy with different surface topographies via plasma electrolytic oxidation

Abstract

This work was made to investigate how nucleation and growth behavior of the coating film were affected by surface topographies of Mg–Al–Zn alloy substrate during the initial stage of plasma electrolytic oxidation (PEO). To satisfy this end, a single substrate was prepared by mechanical treatment exhibiting rough and smooth regions with an equal area on the surface. The rough region with prominent hills and grooves induced the breakdown of passive film, which was indicated by an early appearance of plasma discharge on the rough region since nucleation of coating film occurred preferentially around the hills. However, the coating film grown on the grooves was somewhat thicker and more porous than the film grown on the hills and smooth regions. This was due to the fact that the growth of the coating film was found to be localized in the presence of rough region, which was in line with the discharge activities. Herein, the nucleation and growth behavior during the initial stage of PEO will be discussed schematically on the basis of microstructural interpretation.