T6 Condition Research Articles

A Critical Review on Heat Treatment of Aluminium Alloys

In the modern world, smart materials play a vital role. There are many methods to improve the mechanical and material properties, one among them is by reinforcing different materials into aluminium. Without reinforcing the material, properties can be altered by heat treatment. Age hardening is done for the aluminum and its alloys. Only 2XXX, 6XXX, and 7XXX are heat treatable. The Al2024 alloy is solution heat-treated (T3&T6) with different temperatures and aging exhibits optimum strength and hardness due to the presence of coherent Guinier Preston (GP) zones and ultrafine grains of Nano-sized S-phase (Al2CuMg) precipitates. Hardness can be improved by coating technique later persisting with artificial aging, restricting the cooling rate and heat transfer. The Al6061 is solution heat-treated (T4&T6) and artificially aged; here Al6061 alloy is treated with T4 results in higher formability but lower yield strength whereas T6 treated results in lower formability but higher yield strength. The tensile strength and yield strength of the Al 6XXX series vary accordingly 6005 > 6106 > 6063 > 6061. The 7XXX series alloys are treated with precipitation hardening which improves stress corrosion cracking, hardness, reduces ductility, and ultimate tensile strength. To overcome SCC retrogression and re-aging, which has similar microstructure precipitates of T6 and over-aged T7 condition, Double aging > RR > T6 condition methodology. The current work has the collective details of the effects of heat treatment on aluminum alloy and its composite material.

Effect of Secondary Aging of AA7075 Aluminum Alloy to Hardness

In this study, one of the major aluminum alloys AA7075 was held to obtain the maximum benefit for structural parts. Nowadays for the energy efficiency of vehicles like electric cars or aerospace vehicles weight reducing efforts are needed. To obtain lighter structures specific strengths are gaining importance. In our study, AA 7075 aluminum alloy was processed with additional heat treatment rather than T6 condition to obtain high strength. According to our previous studies, statistical methods seemed very useful to predict probable strength very precisely, for this reason, Box-Behnken Surface Response Method was used. By applying statistical methods, the artificial aging temperature and time were optimized. According to optimized temperature and time, the secondary aging heat treatment was done. In this study three T6 conditions 150, 200, and 250 oC with four treatment times, 1,2,4 and 6 hours were chosen and applied. The secondary aging temperature and time were obtained from Box-Behnken optimization study results and found as 182 oC and 2 hours were applied to all samples. As a result, after secondary aging heat treatment maximum hardness of 151 Hv was obtained from samples that aged at 150 oC, and 250 °C for 1 hour, which is almost doubled because the T6 aged sample has a hardness value of 86 Hv. This is obvious that the strength almost doubled, therefore it is possible to use sections almost half of the T6 condition samples.

Achieving ultra-high strength of Al-Cu-Li alloys by the combination of high pressure torsion and age-hardening

The combined strengthening effects of high pressure torsion (HPT) and age hardening on a recently developed 3rd generation Al-Cu-Li alloy was investigated. Solution treated samples were processed through HPT at room temperature, followed by low temperature artificial ageing (i.e. T4-HPT-AA). A micro-hardness of ∼ 240 Hv was achieved on ageing at 110 oC/60h after HPT. A further improvement in the hardness to ∼ 260 Hv was accomplished by a pre-ageing 110 oC/24h before HPT combined with a post-HPT ageing process at 110 oC for 180h (i.e. T6-HPT-AA). These novel multi-stage processes give rise to an increase in hardness by a factor of 2 as compared to the T4 condition (∼ 120 Hv). After HPT the grain size was dramatically refined to the ultrafine-grained (UFG) structure, accompanied by a large amount of dislocations. No long-range ordered precipitates were observed after HPT and subsequent ageing treatments. Instead, atom probe tomography (APT) provided clear evidence that Cu-Mg co-clusters were homogeneously distributed in the matrix of T4 and T6 processed samples and they segregate strongly to the grain boundaries (GBs) during HPT. Further ageing treatment after HPT leads to the segregation of clusters to dislocations. A strengthening model that incorporates dislocation hardening, grain boundary hardening, solid solution strengthening and a new short-range order strengthening mechanisms was used to predict the yield strength of the alloy. This model indicates that the combined effect due to all three types of Cu-Mg clusters (clustering in matrix, clustering at GBs and at dislocations) is dominant for the strength in all conditions.

Microstructural-micromechanical correlation in an Al–Cu–Mg–Ag–TiB2 (A205) alloy: additively manufactured and cast

In this paper, the processing-structure-property correlation of a high-strength titanium-modified aluminum-copper alloy, i.e., Al–Cu–Mg–Ag–Ti–B (A205), in the laser powder-bed fusion (LPBF) and casting conditions are studied. The as-fabricated and heat-treated materials were considered for this study. As A205 is a heat-treatable aluminum alloy, the effects of different post-fabrication heat-treatment processes, (i) solution heat-treatment (SHT: 520°C for 2 h) and (ii) over-aging and stabilizing treatment (T7), were also assessed. To test the stated relationship in LPBF and cast conditions depth-sensing indentation testing and extensive structural analyses were performed. The morphology and distribution of precipitates and nanoparticles in the microstructure were analyzed using optical, scanning electron, and transmission electron microscopy. The average nanoindentation hardness at as-fabricated, SHT, and T7 conditions are 1.48 ± 0.04, 1.50 ± 0.03, and 1.56 ± 0.06 GPa for the LPBF samples and 1.34 ± 0.04, 1.52 ± 0.10, and 1.72 ± 0.09 GPa for the cast samples. Detailed microstructural analyses confirmed the presence of precipitates and reinforced particles and revealed their morphology. The fine equiaxed grains with the average grain size of 1.1 ± 0.4 μm in the as-built condition highly enhanced the mechanical properties compared to the cast counter material, where the average grain size was measured as 46.4 ± 10.5 μm. Heat treatment played a more effective role on the cast samples and the strength of the cast material exceeded the LPBF material considerably after T7 treatment. This study offers a new compositional window for the additive manufactured lightweight high-strength material categories for various applications including automotive and aerospace industries. Besides, our findings demonstrate the significance of controlling the precipitates through the post-fabrication heat treatment processes.

Studies on Microstructural Evolution and Wear Behaviour of AlNi intermetallic Reinforced AA6061 alloy in T6 condition

Studies on Microstructural Evolution and Wear Behaviour of AlNi intermetallic Reinforced AA6061 alloy in T6 condition

Influence of post-processing techniques on the microstructure, properties and surface integrity of Al Si Mg alloy processed by laser powder bed fusion technique

The present work investigates the influence of post-processing techniques such as heat treatments (T5 and T6 conditions) and the shot peening (SP) under peening pressures such as 3 bar (SP-3) and 6 bar (SP-6) on the LPBF processed AlSi10Mg alloy. The microstructures of as-printed and heat-treated samples revealed a density of greater than 99.9%. The micro-hardness, yield and tensile strength properties were similar in both as-printed and heat-treated (T5) conditions. However, the samples of the heat-treated (T6) showed lower micro-hardness, yield and tensile strength properties than as-printed and heat-treated (T5) samples. There was a significant decrease in surface roughness and a notable improvement in surface hardness for shot-peened samples compared to the as-printed samples. SP process decreased the surface roughness parameter values by more than about ~50% compared to the as-printed samples. The SP-3 condition induced a smoother surface (~12%) than the SP-6 condition on the LPBF processed AlSi10Mg samples. Overall, the employed post-processing techniques such as heat treatment and shot peening on the LPBF processed AlSi10Mg alloy exhibit improved isotropic mechanical properties and surface integrity. • Post-processing techniques such as heat treatments and the shot peening on the LPBF processed AlSi10Mg alloy is studied. • The micro-hardness and tensile properties of T5 were higher than T6 conditions. • SP process decreased the surface roughness by more than about ~50% compared to the as-printed samples. • The SP-3 condition induced a smoother surface (~12%) than the SP-6 condition.

High speed manufacturing of aluminum alloy 7075 tubing by Shear Assisted Processing and Extrusion (ShAPE)

Shear assisted processing and extrusion (ShAPE) was used to extrude aluminum alloy 7075 tubing at speeds up to 12.2 m/min without surface tearing. This work presents the first experimental evidence for high-speed extrusion of 7075, which improves upon conventional extrusion where 2.0 m/min is the limit. The increased speed is primarily attributed to more extensive shear deformation, compared to conventional extrusion, which results in a high density of low angle grain boundaries that facilitate continued deformation and delay the onset of surface tearing. Mechanical testing after heat treating to the T6 condition provided an ultimate tensile strength of 565.3 ± 4.6 MPa, yield strength of 495.7 ± 8.7 MPa, and elongation of 16.4 ± 1.0%. Strength values exceed the ASTM International minimum standard and are on par with American Society for Metals (ASM) typical values, while elongation was substantially improved compared to 7 and 11% for the ASTM and ASM values respectively. It was observed that low temperature extrusion at 341 °C and 40 rpm gave superior material properties in the T6 condition compared to high temperature extrusion at 441 °C and 120 rpm because of variances in nanoscale second phase size and distribution.

Nonequilibrium effects in high enthalpy gas flows expanding through nozzles

An approach based on the direct simulation Monte Carlo method is proposed to model a core flow in a converging–diverging nozzle. The area of applicability of this approach is defined by the Boltzmann equation, which allows fully kinetic models that accurately capture thermal and chemical nonequilibrium to be applied to gas flows where the flow regime rapidly changes from continuum to transitional. The approach is validated through comparison with available experimental data. The examination of nonequilibrium and reaction rate effects for Caltech's T5 shock tunnel condition has shown little impact of nonequilibrium but demonstrated significant sensitivity of nitric oxide (NO) density to all exchange reaction and NO recombination rates. The use of the most recent theoretical and experimental rates results in a factor of two lower NO density at the nozzle exit as compared to the conventional Park rates, which indicates that re-visiting of the latter may be necessary. Multi-parametric sensitivity study of T5 conditions has not provided an explanation for a large drop in free-stream temperature and NO density over time, under constant flow velocity, observed recently in T5. Modeling of High Enthalpy Shock Tunnel Göttingen conditions has demonstrated considerable nonequilibrium between vibrational modes of N2, NO, and O2; it has also shown that the vibration–dissociation coupling strongly influences mole fractions of NO and O2.

Stepwise modelling method for post necking characterisation of anisotropic sheet metal

Modelling and simulation are important tools during design and development processes. For accurate predictions of, e.g. manufacturing processes or final product performance, reliable material data is needed. Usually, the applied material models are calibrated by utilising direct methods such as conventional uniaxial tensile/compression tests but also inverse methods are occasionally applied. Recently, an effective inverse method, the stepwise modelling method (SMM), was presented. By using SMM, the flow stress from initial yielding, beyond necking to final fracture, can be determined. However, the method is developed for sheet materials having isotropic von Mises hardening. In this paper the SMM is extended for post necking characterisation of anisotropic sheet metals using the Barlat yield 2000 criterion. The novel method was applied to analyse the post necking plasticity of the widely used aluminium alloy AA6016 in T4 condition and the aluminium alloy AA5754 in H111 condition. The latter alloy has reported to show serrated yielding, also known as the Portevin–Le Chatelier effect. The obtained flow stress curves agree well with the curves form conventional uniaxial tensile tests up to the point of necking and show credible post necking predictions to final fracture. Furthermore, SMM showed that it could handle the effect of serrated yielding for AA5754-H111. Hence, the novel approach can be used to characterise the post necking hardening of a variety of anisotropic sheet metals and thereby contributes to efficient and reliable material model calibration.

The influence of room temperature storage on intergranular corrosion susceptibility of AA6082 Al-Mg-Si alloy

The influence of room temperature (RT) storage on the microstructure and intergranular corrosion (IGC) behaviour of AA6082-T4 alloy is investigated by the combination of electron microscopy, electrochemical measurement and immersion testing. After 10 months storage at RT, precipitation of β’ phase and segregation of Mg had occurred at high angle grain boundaries (HAGBs) in the alloy that was in T4 condition, leading to an increased IGC susceptibility, which is even higher than that for the alloy in T6 condition.

Arsenic Accumulation in Rice Grain as Influenced by Water Management: Human Health Risk Assessment

Rice is a staple food for humans and a key source of soil arsenic (As) transfer to the human food chain. As a result, it is critical to develop ways for reducing As accumulation in rice. A pot experiment with seven different water management practices was done to examine the impacts of water management on rice (cv. BRRI dhan28) growth, yield, and As accumulation in rice grain. Any health risk due to As accumulation in rice grain was also determined. The soil used in the experiment was artificially contaminated with As and the source of As was sodium arsenate (Na2HAsO4 7H2O). Water management practices affect different plant growth and yield parameters including filled grains per panicle, unfilled grains per panicle, 1000-grain weight, grain yield and straw yield of rice. The number of filled grains per panicle and 1000-grain weight were found to be at their highest in the T7 (alternate wetting and drying) condition, whereas the number of unfilled grains per panicle was at its lowest in the same treatment. The T7 also demonstrated the highest grain yield (21.08 g/pot) and straw yield (22.02 g/pot), whereas the lowest values were noted in T1 (flooding throughout the growth period). The highest As concentration in rice grain (0.52 mg kg−1) was found in T1 and the lowest As concentration in grain (0.27 mg kg−1) was found in T7. Estimation of the human health risk revealed that the non-carcinogenic risks (HQ > 1) and carcinogenic risks (CR > 1.0 × 10−4) were greatly affected by different water regimes. The rice plant grown under alternate wetting and drying condition (T7) showed the lowest health risks compared to other water management practices. Thus, alternate wetting and drying conditions are a good water management strategy for increasing rice output while reducing arsenic buildup in rice grain.

Mechanism of microstructure and texture evolution during shear loading of AA6063 alloys

The cyclic shear test of 6063 aluminum alloys under T4 and T6 conditions was carried out at room temperature. The microstructure and texture evolution were investigated using electron backscattered diffraction (EBSD) at several instances during cyclic shear deformation. Hardly any change in grain size was observed during the cyclic shear test of T4 and T6 samples. The local residual strain distribution measured in the form of average kernel misorientations (KAM) values increases continuously with an increase in shear strain for both samples. The increase in KAM value was higher for the T6 sample compared to the T4 sample during forward (F) shearing. On reversing the loading path, the increase in KAM value was higher for forward + reverse (FR) and forward + reverse + forward (FRF) straining of the T4 sample compared to the T6 sample. The cube texture was found to be unstable during shear deformation. A significant rotation of texture was observed in both T4 and T6 samples. However, the extent of rotation was slightly greater for the T6 sample as compared to the T4 sample. It was observed that the latent hardening of (1-11)<101>was more than (111)<1-01>in the T4 sample. Similarly, the latent hardening of (1-1-1)<011>was more than the (111)<1-01>in the T6 sample. The origin of latent hardening was attributed to the formation of sessile jogs during dislocation-dislocation interactions on different planes of T4 samples and the difference in volume fraction of precipitates on different planes of T6 samples. The mechanical properties show that the 0.2% YS increases with subsequent reverse and forward shearing for the T4 sample. However, the 0.2% YS during subsequent reverse shearing is lower than the initial forward shearing for the T6 sample. This decrease in yield stress upon loading reversal is attributed to the presence of deformation-induced intragranular back stresses within the T6 material. It is observed that the rate of cross slip of dislocations depends on the athermal dislocation content, presence of dislocation debris in the unfavorable grains, and the difference in the latent hardening values of different slip systems for the T4 and T6 materials.

Numerical and experimental investigations on the effect of target thickness and solution treatment on the ballistic behaviour of AA7075 thick plates

The influence of target thickness and solution treatment on the ballistic behaviour of AA7075 targets has been investigated by both numerical and experimental methods. In numerical simulation, the target thickness was varied from 19 to 26 mm and an Ogive nose shaped projectile of 7.62 mm diameter with inlet velocities ranging between 800–875 m/s was considered. In order to justify the numerical observations, high velocity ballistic experiments were conducted on AA7075-T651 and the solution treated plates of various thicknesses (12, 16, 18, 20, 22 and 25 mm). For this experimental study, a deformable form projectile with dimensions of 7.62 × 51 mm and an inlet velocity of 850 ± 20 m/s was used. Microstructures of ballistic test samples were analysed using an optical microscope. Numerical analysis using ABAQUS predicted the minimum thickness required to resist complete penetration to be 20 mm in the case of AA7075 plates in the T651 condition, while experimental results showed it to be 21 mm. In the case of AA7075 solution treated plates, numerical simulation analysis predicted the minimum required plate thickness to resist complete penetration to be 24 mm, while the experimental results showed it to be 23 mm. Post ballistic microstructure analysis revealed that there was no change in the microstructure in the AA7075-T651 condition plates. Solution treated plates showed deformation of grains nearer to the impact region with the formation of adiabatic shear bands. In the case of the T651 plate, the mode of fracture was brittle, resulting in splinters, whereas it was petalling in the case of the solution-treated plates. The numerically predicted depth of penetration on both targets was reasonably close to experimental results with an average of 4% error.

Study of microstructure and mechanical behaviour of aluminium alloy hybrid composite with boron carbide and graphene nanoplatelets

Lightweight materials with superior designs and improved properties have always been in demand of the aerospace and automobile industries for improved performance. Spark plasma sintering was employed in the present study for the fabrication of a hybrid composite of boron carbide and graphene nanoplatelets. Reference samples and composites with 0.1 wt% GNPs, 1 wt% B4C and hybrid combination containing 0.1 wt% GNPs and 1 wt% B4C in Al6061 matrix were prepared. All the samples were divided into two groups, namely; as fabricated and artificially age hardened (T6). Electron backscattered diffraction technique was employed to evaluate the microstructure along with the optical and scanning electron microscopy. Various illustrative models have been conceived to describe the physical behaviours of the composites. Improvements in hardness (33% & 50%) and tensile strength (11% & 20%) were exhibited by the hybrid composite in F and T6 conditions, respectively. The strengthening mechanism is explained with the help of fractography. The fractured surfaces revealed uniform distribution of reinforcements and extensive crack deflection.

Crystal plasticity modeling for mechanical property prediction of AA2195-T6 friction stir welded joints

The gradient material exposure to frictional heat and plastic flow during friction stir welding leads to local variations in microstructure and mechanical properties among different joint zones. This study aims to predict strengthening contributions of local microstructural evolutions including precipitate distribution, crystal morphologies, grain size, and dislocation density for friction stir welded joints of AA2195-T6. These effects are included by a unified microstructure-sensitive physics-based constitutive modeling approach into joint local variations in yield strength, plastic hardening, and ultimate tensile strength. Local precipitate phase distributions are observed by the transmission electron microscopy method. X-ray diffraction process is conducted to measure joint local variations in dislocation density. Electron backscattered diffraction mapping is utilized to observe joint local crystal morphologies. Evolutions in the crystal slip strength due to each of mentioned microstructure attributes are inserted into a crystal plasticity finite element frame work. Modeling parameters are calibrated for AA2195-O and T6 conditions, and simulated outputs are validated by comparing with experimentally observed joint local tensile properties using the digital image correlation method. Subsequently, obtained local tensile properties in the grain scale are inserted into a macroscale global model containing all friction stir welded joint areas. An acceptable match is observed between simulated and experimentally obtained data on local and global friction stir welded joint tensile stress-strain curves and tensile failure location.

Fatigue Behavior of an Al-12.7Si-0.7Mg Alloy Processed by Extrusion and Heat Treatment

The fatigue life of a hot extruded Al-12.7Si-0.7Mg alloy under T1, T4, and T6 conditions was studied. The microstructure and tensile properties of the alloy were investigated in order to analyze the fatigue behavior. The results of the fatigue test showed that an extruded Al-12.7Si-0.7Mg alloy provided greater fatigue life compared to a cast Al-Si alloy, which was explained by the refined microstructure characterized by fine Si particles uniformly distributed in the Al matrix of fine equiaxed grains promoted by hot extrusion. The fatigue property of the alloy in T6 treatment was higher than that in the T4 and T1 conditions due to strengthening precipitation.

Effect of the heat treatment on the microstructure and hardness evolution of a AlSi10MgCu alloy designed for laser powder bed fusion

The aim of this work is to investigate the influence of the addition of Cu on the microstructure and on the microhardness of a laser powder bed fusion (L-PBF)-fabricated AlSi10MgCu alloy. With this goal, AlSi10Mg+4 wt%Cu pre-alloyed powder was produced by gas atomization. Following a parameter optimization study, dense as-built specimens with a high relative density of 99.8% were fabricated. An outstanding microhardness value, exceeding 180 HV, was obtained after aging at 160 °C for 16 h. This value is similar to that of the high strength Al 7075 in the T6 condition. With the aid of analytical transmission electron microscopy, it was concluded that the origin of the observed excellent mechanical behavior could be attributed to the beneficial effect of Cu in reducing the Al-matrix cell size, and in increasing the density and decreasing the size of the Si-based nanoprecipitates at cell interiors. More specifically, it is proposed that the maximum hardness is associated to the development of Cu-rich GP-I zones, which act as precursors of Si nanoprecipitates. Overaging leads to a reduction in microhardness due to transformation of these GP-I zones into coarser θ’’ precipitates and thus to a smaller volume fraction of larger Si-based nanoparticles.

Effects of equal channel angular pressing and heat treatments on the microstructures and mechanical properties of selective laser melted and cast AlSi10Mg alloys

This study investigated the impact of the equal channel angular pressing (ECAP) combined with heat treatments on the microstructure and mechanical properties of AlSi10Mg alloys fabricated via selective laser melting (SLM) and gravity casting. Special attention was directed towards determining the effect of post-fabrication heat treatments on the microstructural evolution of AlSi10Mg alloy fabricated using two different routes. Three initial alloy conditions were considered prior to ECAP deformation: (1) as-cast in solution treated (T4) condition, (2) SLM in T4 condition, (3) SLM subjected to low-temperature annealing. Light microscopy, transmission electron microscopy, X-ray diffraction line broadening analysis, and electron backscattered diffraction analysis were used to characterize the microstructures before and after ECAP. The results indicated that SLM followed by low-temperature annealing led to superior mechanical properties, relative to the two other conditions. Microscopic analyses revealed that the partial-cellular structure contributed to strong work hardening. This behavior enhanced the material’s strength because of the enhanced accumulation of geometrically necessary dislocations during ECAP deformation.

Effect of heat treatment on microstructure and tensile properties of die-cast Al-Cu-Si-Mg alloys

The effects of T5 and T6 heat treatment on the microstructural development and mechanical properties of newly developed die-cast Al-xCu-2.2%Si-1.1%Mg (x=5, 6.6 and 10.6, in wt%) alloys were investigated. After T5 heat treatment to peak hardness, the main precipitates changes from β’’ in Al5Cu to β’’ and θ’ in Al6.6Cu and then to θ’ and Q’’-type precipitate in Al10.6Cu, due to the various Cu content in the α-Al matrix. The highest yield strength of 395±5 MPa and lowest elongation of 1.9±0.15% have been achieved in Al10.6Cu after peak-aged T5 condition as compared to other Al-Cu-Si-Mg alloy compositions. The solution treatment of Al-Cu-Si-Mg alloys for 30–60 min at 500 °C dissolves a sufficient quantity of Cu (~3 wt%), and spheridises the Al2Cu and Al5Cu2Mg8Si7 phases. A large number of θ’ and Q’’ coexist inside the α-Al matrix after T6 heat treatment, contributing to the exceptionally high mechanical strength. The T6 peak ageing time increased from 10 h in Al5Cu to 14 h in Al10.6Cu. These newly developed aluminium die-cast alloys having excellent mechanical properties that exceed those in existing aluminium die-cast alloys after heat treatment. Especially, the excellent yield strength of 427 MPa and 444 MPa, as well as elongation of 4.4% and 4.1%, were achieved in Al5Cu and Al6.6Cu after T6 heat treatment, respectively.

INVESTIGATION OF THE EFFECTS OF DIFFERENT RETROGRESSION AND RE-AGING PARAMETERS APPLIED TO THE 7075 ALLOY ON THE MICRO-ARC OXIDATION PROCESS

In this paper, retrogression and re-aging (RRA) heat treatment was applied to 7075 aluminum alloy in T6 condition at different times (30 and 90[Formula: see text]min) and temperatures (180∘C and 240∘C). While RRA heat treatments increase the corrosion resistance of the material, it does not harm its mechanical properties. On the other hand, the surface resistance of aluminum is low. Surface modifications are applied to overcome this deficiency. Among these, the micro-arc oxidation (MAO) method increases the corrosion resistance and attains excellent values in surface hardness. To better understand the RRA/MAO relationship, heat-treated (RRA) samples with four different parameters were coated with the MAO method. In this way, a ceramic oxide coating layer was created on the material surfaces. In order to determine the RRA parameter effect, the MAO process parameters are kept constant (anode voltage ([Formula: see text]): 500[Formula: see text]V, cathode voltage ([Formula: see text]): 300[Formula: see text]V, anode voltage open time ([Formula: see text]: 300[Formula: see text][Formula: see text]s, cathode voltage open time ([Formula: see text]): 200[Formula: see text][Formula: see text]s, frequency: 160 coating with Hz, and process time: 20[Formula: see text]min). Surface properties (coating thickness, surface roughness, surface arc duct’s structure, etc.), phase analysis (X-ray diffraction (XRD)) and microstructures (coating cross-section studies: distance-dependent hardness, coating/backing material interface character, coating porosity ratio) were examined. XRD analysis showed that the main phase of the coatings is [Formula: see text]-Al2O3. A coating layer of around 125[Formula: see text][Formula: see text]m was achieved with the growth rate of 6[Formula: see text][Formula: see text]m/min. Surface roughness was between 5.5[Formula: see text][Formula: see text]m and 8[Formula: see text][Formula: see text]m for different RRA parameters. RRA/MAO relation with the characterization made was detailed, and predictions were made for the surface properties of the material (hardness, corrosion resistance, wear, etc.).