Abstract: The voltage-current properties during plasma electrolytic discharge were determined by measuring the current density and cell voltage as functions of processing time and then by mathematical transformation. Correlation between discharge I-V property and the coatings microstructure on aluminum alloy during plasma electrolytic oxidation was determined by comparing the voltage-current properties at different process stages with SEM results of the corresponding coatings. The results show that the uniform passive film corresponds to a I-V property with one critical voltage, and a compound of porous layer and sintered ceramic particles corresponds to a I-V property with two critical voltages. The growth regularity of PEO cermet coatings was also studied.

Key words: plasma electrolytic oxidation; discharge property; voltage—current curve; ceramic coating; aluminum alloy