The incorporation of ZnO nanoparticles into plasma electrolytic oxidation coatings formed on aluminum was investigated in this work. The coating process was performed in silicate-based electrolytes containing varying amounts of ZnO nanoparticles. A current density of 5 A dm−2 with a low duty cycle of 20% and a frequency of 2000 Hz were applied to all aluminum samples. Results showed all coatings were primarily comprised of γ-Al2O3, Al2H2O12S4 (Al2O3.4SiO2.H2O) and contained ZnO nanoparticles from the electrolyte. Surface and cross-sectional elemental maps revealed that ZnO nanoparticles were distributed primarily on the coating surface and near the coating-substrate interface. It has been proposed that formation of silica insoluble gel containing entrapped ZnO nanoparticles on the coating surface is a reason of why Zn and Si were primarily concentrated in the upper parts of the coatings. Beside this, particles can only reach the inner layer of the coating through short-circuit paths formed by breakdown events. In pulsed-unipolar DC current mode with low duty cycle and corresponding large number of micro-discharges, higher number of nanoparticles can enter discharge channels and reach the inner parts of the coating. Potentiodynamic polarization test results showed embedding nanoparticles in the coating structure improves its corrosion behavior.