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In this study, a plasma electrolytic oxidation (PEO) process was used to produce oxide coatings on commercially pure aluminium (1100 alloy) at a pulsed dc power mode. The effects of process parameters (i.e. current density and treatment time) on the plasma discharge behaviour during the PEO treatment were investigated using optical emission spectroscopy (OES) in the visible and near ultraviolet (NUV) band (285–800 nm). The elements present in the plasma were identified. Stark shifts of spectral lines and line intensity ratios were utilized to determine the plasma electron concentrations and temperatures, respectively. The plasma electron temperature profile, coating surface morphology and coating composition were used to interpret the plasma discharging behaviour. The different coating morphologies and compositions at different coating surface regions are explained in terms of three types of discharge, which originate either at the substrate/coating interface, within the upper layer, or at the coating top layer. The high spike peaks on the plasma intensity and temperature profiles corresponded to discharges originated from the substrate/coating interface, while the base line and small fluctuations were due to discharges at the coating/electrolyte interface.

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Digital video imaging of the plasma electrolytic oxidation (PEO) of aluminium has been performed, which allowed evaluation of both dimensional characteristics of individual microdischarges appearing at the oxide–electrolyte interface and their collective behaviour throughout the oxidation process. It has been shown that the microdischarge cross-sectional dimensions vary within the range 0.01–1.35 mm2. In the course of PEO processing, small localized events (<0.03 mm3) always dominate in the microdischarge spatial distribution and the relative proportion of medium-sized to very large microdischarges is gradually redistributed in favour of the latter. Temporal dependences have been found for the fraction of surface area instantaneously experiencing the discharge, as well as for the spatial and current densities of the microdischarge. Discharge mechanisms occurring during PEO are discussed and a model of microdischarge formation is suggested, assuming the possibility of free-electron generation and glow discharge ignition in the gaseous media developed at the oxide–electrolyte interface. First approximation evaluations of thermal processes in the oxide layer under the discharge conditions have been considered. The estimated ranges of the microdischarge current density (50–18 kA m−2) and duration (0.25–3.5 ms) sufficient for initiating phase transitions (e.g. γ–α transformation and melting) in the surface oxide layer are shown to be in good agreement with experimental data.

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