Corrosion and wear resistance of coatings produced on AZ31 Mg alloy by plasma electrolytic oxidation in silicate-based K₂TiF₆ containing solution: Effect of waveform

In this research, plasma electrolytic oxidation coatings were prepared on AZ31 Mg alloy in a silicate-based solution containing K₂TiF₆ using bipolar and soft sparking waveforms with 10, 20, and 30% cathodic duty cycles. The coatings displayed a net-like surface morphology consisted of irregular micro-pores, micro-cracks, fused oxide particles, and a sintered structure. Due to the incorporation of TiO₂ colloidal particles and the cathodic pulse repair effect, most of the micro-pores were sealed. Long-term corrosion performance of the coatings was investigated using electrochemical impedance spectroscopy during immersion in 3.5 wt.% NaCl solution up to 14 days. The coating grown by the soft sparking waveform with a 20% cathodic duty cycle having the lowest porosity (6.2%) and a sharp layer concentrated in F element at the substrate/coating interface shows the highest corrosion resistance. The friction coefficient of this coating has remained stable during the sliding even under 5 N normal load, showing relatively higher wear resistance than other coatings. The coating produced using the equivalent unipolar waveform, as the reference specimen, showed the highest friction coefficient and the lowest wear resistance despite its highest micro-hardness.