Anodic processes in plasma electrolytic oxidation of aluminium in alkaline solutions

In this paper, basic electrochemical processes (such as oxide film growth, anodic dissolution and oxygen liberation) on an aluminium anode in a model alkaline solution are considered under conditions of galvanostatic DC plasma electrolytic oxidation (PEO). The experiments performed include: (i) recording and analysis of the main electrical characteristics of the process; (ii) determination of the oxide layer thickness; (iii) anodic gas collection and composition analysis and (iv) electrolyte analysis to determine dissolved aluminium. Four different stages of the PEO process have been identified, characterised by various rate proportions of the partial anodic processes. Overall current efficiency of the oxide film formation has been estimated to be in the 10-30% range. The film growth rate decreases significantly with increasing electrolyte concentration from 0.5 to 2 gl^-1 KOH, since the rate of anodic dissolution increases. Oxygen evolution is shown to be the main electrochemical process at the potentials corresponding to the plasma stages of the electrolysis. The overall rate of oxygen liberation at the anode exceeds the Faraday yield, which is probably due to the radiolytic effect of the plasma discharge on the adjacent electrolyte volume.