In this study, we examined how current density, sodium phosphate concentration, and the addition of copper sulfate to the supporting electrolyte affect PEO coatings on pure titanium. The chemical composition, morphology, and optical behavior of PEO coatings were extensively analyzed using scanning electron microscopy (SEM), X-ray diffraction (XRD), and UV–Vis diffuse reflectance spectroscopy (DRS). With an increase in current density from 6 to 18 A/dm2, the coating's pore size enlarges and the rutile phase content within the coatings increases. The coating created at 12 A/dm2 shows the highest photocatalytic activity and triggers a unique three-stage behavior in the voltage-time diagram. Adding 4 g/l of CuSO4 to the electrolyte resulted in the formation of an unwanted Cu-based precipitates, causing electrolyte instability. To stabilize it, potassium hydroxide was removed, and the base electrolyte concentration was adjusted. To address this issue, potassium hydroxide was eliminated from the supporting electrolyte. Subsequently, the concentration of the base electrolyte was optimized. Also, the synergistic influence of CuSO4 addition (4 g/l) to the supporting electrolyte at different concentrations of 5, 10, and, 15 g/l of trisodium phosphate on PA was investigated. The superior photocatalytic performance of the optimum coating created in the electrolyte containing 5 g/l trisodium phosphate and 4 g/l CuSO4 is attributed to its enhanced porous structure, along with the heterojunction between the anatase and rutile phases. These features significantly boost the available surface area and facilitate the efficient separation and transfer of photogenerated charge carriers. Ultimately, a mechanism for MB photodegradation was proposed based on the findings from Mott-Schottky analysis and DRS.
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