The Influence of In Situ Anatase Particle Addition on the Formation and Properties of Multifunctional Plasma Electrolytic Oxidation Coatings on AA2024 Aluminum Alloy

Plasma electrolytic oxidation (PEO) with in situ anatase particle addition is applied to functionalize the surface of AA2024 alloy. A base potassium titanium oxide oxalate dihydrate aqueous electrolyte is used with up to 30 g L−1 anatase particle addition. The coatings’ morphology and phase composition as a function of the anatase concentration in the electrolyte are characterized by scanning electron microscopy (SEM), X‐ray diffraction (XRD), and glow discharge optical emission spectroscopy (GDOES). Photocatalytic activity, stability in chloride solution, and tribological properties are also determined. The main coating forming phases are anatase and rutile on top of a mixed interface region consisting of TiAl2O5 as reaction product between the TiO2 and an Al2O3 barrier layer on top of the Al substrate. The mixed layer is extending with increasing amount of particles added, due to intensified discharges. In addition, anatase‐to‐rutile phase ratio increases due to the additional anatase particles in the electrolyte. Thus, the photocatalytic activity is improving with the particle addition. The coatings’ mechanical resistance is dropping first before increasing again with more particles added. Chemical and restored mechanical stability seems to be related to the extended mixed interface formation, which strengthens the bond to the substrate when more particles are added. TiO2‐based plasma electrolytic oxidation (PEO) is successfully formed on the surface of AA2024 alloy to functionalize it. K2[TiO(C2O4)2]·2H2O aqueous electrolyte with anatase powder addition is used for the direct formation of photoactive TiO2 surface layer, which additionally provides improved corrosion and wear resistance to the soft and active substrate material. Fundamental mechanism of PEO layer formation is suggested.