Frequency-dependent microstructural characteristics and corrosion behavior of oxide coatings on Ti-6Al-4V alloy fabricated by plasma electrolytic oxidation

Document Type : Research Paper

Authors

Department of Materials Engineering, Bu-Ali Sina University, Hamedan, 65178-38695, Iran.

10.22059/jufgnsm.2023.02.07

Abstract

This study investigated the influence of three different frequencies (100, 1000, and 2000 Hz) during the PEO process on the characteristics of ceramic coatings fabricated on Ti-6Al-4V alloys in the presence of 12 g/L Na3PO4.12H2O and 3 g/L ZrO2 nanoparticles. The microstructure, surface roughness, wettability, chemical composition, and corrosion performance of the coatings were thoroughly examined to assess their performance. The microstructural results revealed that increasing frequencies led to a reduction in the porosity size, as well as a decrease in coating thickness, wettability, and surface roughness. Additionally, the corrosion performance of the coatings was evaluated in Hank's solution using electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization (PDP) methods. As the frequency rose from 100 to 2000 Hz, the corrosion current density dropped significantly from 47.35 to 13.75 nA/cm2 and the corrosion potential increased from 218 to 684 mV versus Ag/AgCl electrode. These findings indicated that the coating produced at a frequency of 2000 Hz exhibited the lowest corrosion density, thereby demonstrating superior corrosion resistance compared to the coatings produced at lower frequencies. The corrosion resistance of the optimum coating (coating formed at a frequency of 2000 Hz) was found to be approximately 0.8 times higher compared to the uncoated metal.

Keywords

References

  1. Fattah-alhosseini A, Molaei M. A review of functionalizing plasma electrolytic oxidation (PEO) coatings on titanium substrates with laser surface treatments. Applied Surface Science Advances. 2023;18:100506.
  2. Muhaffel F, Kaba M, Cempura G, Derin B, Kruk A, Atar E, Cimenoglu H. Influence of alumina and zirconia incorporations on the structure and wear resistance of titania-based MAO coatings. Surface and Coatings Technology. 2019;377:124900.
  3. Yerokhin AL, Nie X, Leyland A, Matthews A. Characterisation of oxide films produced by plasma electrolytic oxidation of a Ti–6Al–4V alloy. Surface and Coatings Technology. 2000;130(2-3):195-206.
  4. Roknian M, Fattah-alhosseini A, Gashti SO. Plasma Electrolytic Oxidation Coatings on Pure Ti Substrate: Effects of Na3PO4 Concentration on Morphology and Corrosion Behavior of Coatings in Ringer’s Physiological Solution. Journal of Materials Engineering and Performance. 2018;27(3):1343-51.
  5. Wang J-H, Wang J, Lu Y, Du M-H, Han F-Z. Effects of single pulse energy on the properties of ceramic coating prepared by micro-arc oxidation on Ti alloy. Applied Surface Science. 2015;324:405-13.
  6. Nikoomanzari E, Karbasi M, C.M.A. Melo W, Moris H, Babaei K, Giannakis S, Fattah-alhosseini A. Impressive strides in antibacterial performance amelioration of Ti-based implants via plasma electrolytic oxidation (PEO): A review of the recent advancements. Chemical Engineering Journal. 2022;441:136003.
  7. Attarzadeh N, Kazemi A, Molaei M, Fattah-alhosseini A. Multipurpose surface modification of PEO coatings using tricalcium phosphate addition to improve the bedding for apatite compounds. Journal of Alloys and Compounds. 2021;877:160275.
  8. Aliofkhazraei M, Macdonald DD, Matykina E, Parfenov EV, Egorkin VS, Curran JA, et al. Review of plasma electrolytic oxidation of titanium substrates: Mechanism, properties, applications and limitations. Applied Surface Science Advances. 2021;5:100121.
  9. Wheeler JM, Collier CA, Paillard JM, Curran JA. Evaluation of micromechanical behaviour of plasma electrolytic oxidation (PEO) coatings on Ti–6Al–4V. Surface and Coatings Technology. 2010;204(21-22):3399-409.
  10. Fattah-Alhosseini A, Keshavarz MK, Molaei M, Gashti SO. Plasma Electrolytic Oxidation (PEO) Process on Commercially Pure Ti Surface: Effects of Electrolyte on the Microstructure and Corrosion Behavior of Coatings. Metallurgical and Materials Transactions A. 2018;49(10):4966-79.
  11. Shokouhfar M, Dehghanian C, Montazeri M, Baradaran A. Preparation of ceramic coating on Ti substrate by plasma electrolytic oxidation in different electrolytes and evaluation of its corrosion resistance: Part II. Applied Surface Science. 2012;258(7):2416-23.
  12. Li G, Ma F, Liu P, Qi S, Li W, Zhang K, Chen X. Review of micro-arc oxidation of titanium alloys: Mechanism, properties and applications. Journal of Alloys and Compounds. 2023;948:169773.
  13. Lu X, Mohedano M, Blawert C, Matykina E, Arrabal R, Kainer KU, Zheludkevich ML. Plasma electrolytic oxidation coatings with particle additions – A review. Surface and Coatings Technology. 2016;307:1165-82.
  14. Fattah-alhosseini A, Molaei M, Babaei K. The effects of nano- and micro-particles on properties of plasma electrolytic oxidation (PEO) coatings applied on titanium substrates: A review. Surfaces and Interfaces. 2020;21:100659.
  15. Fattah-alhosseini A, Chaharmahali R, Babaei K. Impressive strides in amelioration of corrosion and wear behaviors of Mg alloys using applied polymer coatings on PEO porous coatings: A review. Journal of Magnesium and Alloys. 2022;10(5):1171-90.
  16. Nikoomanzari E, Fattah-alhosseini A, Pajohi Alamoti MR, Keshavarz MK. Effect of ZrO2 nanoparticles addition to PEO coatings on Ti–6Al–4V substrate: Microstructural analysis, corrosion behavior and antibacterial effect of coatings in Hank's physiological solution. Ceramics International. 2020;46(9):13114-24.
  17. Montazeri M, Dehghanian C, Shokouhfar M, Baradaran A. Investigation of the voltage and time effects on the formation of hydroxyapatite-containing titania prepared by plasma electrolytic oxidation on Ti–6Al–4V alloy and its corrosion behavior. Applied Surface Science. 2011;257(16):7268-75.
  18. Xia Q, Wang J, Liu G, Wei H, Li D, Yao Z, Jiang Z. Effects of electric parameters on structure and thermal control property of PEO ceramic coatings on Ti alloys. Surface and Coatings Technology. 2016;307:1284-90.
  19. Pavarini M, Moscatelli M, Candiani G, Tarsini P, Cochis A, Rimondini L, et al. Influence of frequency and duty cycle on the properties of antibacterial borate-based PEO coatings on titanium for bone-contact applications. Applied Surface Science. 2021;567:150811.
  20. Zhang X, Zhang Y, Chang L, Jiang Z, Yao Z, Liu X. Effects of frequency on growth process of plasma electrolytic oxidation coating. Materials Chemistry and Physics. 2012;132(2-3):909-15.
  21. Karbasi M, Nikoomanzari E, Hosseini R, Bahramian H, Chaharmahali R, Giannakis S, et al. A review on plasma electrolytic oxidation coatings for organic pollutant degradation: How to prepare them and what to expect of them? Journal of Environmental Chemical Engineering. 2023;11(3):110027.
  22. Yerokhin AL, Nie X, Leyland A, Matthews A, Dowey SJ. Plasma electrolysis for surface engineering. Surface and Coatings Technology. 1999;122(2-3):73-93.
  23. Matykina E, Berkani A, Skeldon P, Thompson GE. Real-time imaging of coating growth during plasma electrolytic oxidation of titanium. Electrochimica Acta. 2007;53(4):1987-94.
  24. Aliofkhazraei M, Gharabagh RS, Teimouri M, Ahmadzadeh M, Darband GB, Hasannejad H. Ceria embedded nanocomposite coating fabricated by plasma electrolytic oxidation on titanium. Journal of Alloys and Compounds. 2016;685:376-83.
  25. Yao Z, Jiang Z, Sun X, Xin S, Wu Z. Influence of the frequency on the structure and corrosion resistance of ceramic coatings on Ti–6Al–4V alloy produced by micro-plasma oxidation. Materials Chemistry and Physics. 2005;92(2-3):408-12.
  26. Bala Srinivasan P, Liang J, Balajeee RG, Blawert C, Störmer M, Dietzel W. Effect of pulse frequency on the microstructure, phase composition and corrosion performance of a phosphate-based plasma electrolytic oxidation coated AM50 magnesium alloy. Applied Surface Science. 2010;256(12):3928-35.
  27. Lv G-H, Chen H, Gu W-C, Li L, Niu E-W, Zhang X-H, Yang S-Z. Effects of current frequency on the structural characteristics and corrosion property of ceramic coatings formed on magnesium alloy by PEO technology. Journal of Materials Processing Technology. 2008;208(1-3):9-13.
  28. Xu L, Wu C, Lei X, Zhang K, Liu C, Ding J, Shi X. Effect of oxidation time on cytocompatibility of ultrafine-grained pure Ti in micro-arc oxidation treatment. Surface and Coatings Technology. 2018;342:12-22.
  29. Braem A, Van Mellaert L, Mattheys T, Hofmans D, De Waelheyns E, Geris L, et al. Staphylococcal biofilm growth on smooth and porous titanium coatings for biomedical applications. Journal of Biomedical Materials Research Part A. 2013;102(1):215-24.
  30. Molaei M, Fattah-alhosseini A, Nouri M, Mahmoodi P, Navard SH, Nourian A. Enhancing cytocompatibility, antibacterial activity and corrosion resistance of PEO coatings on titanium using incorporated ZrO2 nanoparticles. Surfaces and Interfaces. 2022;30:101967.
  31. Molaei M, Nouri M, Babaei K, Fattah-Alhosseini A. Improving surface features of PEO coatings on titanium and titanium alloys with zirconia particles: A review. Surfaces and Interfaces. 2021;22:100888.
  32. Shin KR, Ko YG, Shin DH. Influence of zirconia on biomimetic apatite formation in pure titanium coated via plasma electrolytic oxidation. Materials Letters. 2010;64(24):2714-7.
  33. Gowtham S, Hariprasad S, Arunnellaiappan T, Rameshbabu N. An investigation on ZrO2 nano-particle incorporation, surface properties and electrochemical corrosion behaviour of PEO coating formed on Cp-Ti. Surface and Coatings Technology. 2017 Mar 15;313:263-73.
  34. Lv G-H, Chen H, Li L, Niu E-W, Pang H, Zou B, Yang S-Z. Investigation of plasma electrolytic oxidation process on AZ91D magnesium alloy. Current Applied Physics. 2009;9(1):126-30.
  35. Molaei M, Fattah-alhosseini A, Nouri M, Mahmoodi P, Nourian A. Incorporating TiO2 nanoparticles to enhance corrosion resistance, cytocompatibility, and antibacterial properties of PEO ceramic coatings on titanium. Ceramics International. 2022;48(14):21005-24.
  36. Mahlobo MGR, Chikosha L, Olubambi PA. Study of the corrosion properties of powder rolled Ti–6Al–4V alloy applied in the biomedical implants. Journal of Materials Research and Technology. 2022;18:3631-9.
  37. Babaei M, Dehghanian C, Babaei M. Electrochemical assessment of characteristics and corrosion behavior of Zr-containing coatings formed on titanium by plasma electrolytic oxidation. Surface and Coatings Technology. 2015;279:79-91.
  38. Gnedenkov SV, Sinebryukhov SL, Egorkin VS, Mashtalyar DV, Alpysbaeva DA, Boinovich LB. Wetting and electrochemical properties of hydrophobic and superhydrophobic coatings on titanium. Colloids and Surfaces A: Physicochemical and Engineering Aspects. 2011;383(1-3):61-6.
  39. Evgeny B, Hughes T, Eskin D. Effect of surface roughness on corrosion behaviour of low carbon steel in inhibited 4 M hydrochloric acid under laminar and turbulent flow conditions. Corrosion Science. 2016;103:196-205.

 

Journal of Ultrafine Grained and Nanostructured Materials
Volume 56, Issue 2
December 2023
Pages 184-193

Files

History

  • Receive Date: 19 October 2023
  • Revise Date: 09 December 2023
  • Accept Date: 14 December 2023

Share

How to cite

Statistics