High growth rate, wear resistant coatings on an Al–Cu–Li alloy by plasma electrolytic oxidation in concentrated aluminate electrolytes

Plasma electrolytic oxidation of a 2A97 Al–Cu–Li alloy under a pulsed bi-polar constant current regime has been carried out in electrolytes containing 5, 32 and 56gl−1 NaAlO2. Wear resistant coatings, containing relatively large amounts of α-Al2O3, were formed using concentrated solutions. The best protection was obtained with a relatively compact coating, generated with 32gl−1 NaAlO2. The coating growth rate increased from ~1.5 to 11.3μmmin−1 between 5 and 56gl−1 NaAlO2. The high rates indicate that non-Faradaic processes contribute to the coating formation. Increased concentrations of NaAlO2 reduced the energy required for coating formation; e.g. to the range ~1 to 5kWhm−2μm−1 for coatings formed with 32 and 56gl−1 NaAlO2. •PEO of an Al–Cu–Li alloy is investigated in aluminate electrolytes.•A superior wear resistant coating forms in 32gl−1 NaAlO2+1gl−1 KOH.•The compact nature and high α-Al2O3 content contribute to the excellent performance.•Coatings can be formed at high rates with low energy consumption.•Non-Faradaic processes contribute significantly to the coating thickness.