Optimization of the plasma electrolytic oxidation process parameters on 7075 aluminum alloy using Taguchi method
In this study, the objective was to enhance the corrosion resistance of plasma electrolytic oxidation (PEO) coatings on AA7075 alloy by optimizing the PEO process parameters including current density, time, frequency, and duty cycle, using the Taguchi design of experiments method. The optimal values...
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Elsevier
2025-07-01
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| Series: | Journal of Materials Research and Technology |
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| author | Erfan Pirhadi Nouri Saeed Reza Allahkaram Mehrnaz Gharagozlou |
| author_facet | Erfan Pirhadi Nouri Saeed Reza Allahkaram Mehrnaz Gharagozlou |
| author_sort | Erfan Pirhadi Nouri |
| collection | DOAJ |
| description | In this study, the objective was to enhance the corrosion resistance of plasma electrolytic oxidation (PEO) coatings on AA7075 alloy by optimizing the PEO process parameters including current density, time, frequency, and duty cycle, using the Taguchi design of experiments method. The optimal values for these parameters were determined to be 40 A/dm2, 15 min, 1500 Hz, and 30 %, respectively. The influence of each parameter was also discussed, and it was found that the duty cycle was the most significant parameter influencing the corrosion resistance of the PEO coatings. The polarization resistance of the optimized coating reached 105.206 MΩ cm2, which was 49 times higher than the substrate. This improvement indicates an enhanced barrier effect against corrosive agents, suggesting the potential of the optimized PEO coating for use in demanding industrial environments such as aerospace and marine applications. The results of electrochemical impedance spectroscopy (EIS) also indicated an improvement in corrosion resistance. The microstructure and surface morphology of the optimized coating were examined using scanning electron microscopy (SEM) equipped with energy-dispersive X-ray spectroscopy (EDS), which revealed a typical structure of PEO coatings. The porosity of the coating was 3.95 % and the average diameter of micropores was 1.57 μm. The constituent elements of the coating were aluminum, oxygen, silicon, magnesium, and zinc. Additionally, the coating exhibited good adhesion to the substrate, and the thickness of the optimized coating was 9.4 μm. X-ray diffraction (XRD) analysis revealed that the main phases of the coating were gamma-alumina and magnesium oxide. |
| format | Article |
| id | doaj-art-102a3bbfea3e46ea8b68c633d4017783 |
| institution | Kabale University |
| issn | 2238-7854 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | Elsevier |
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| series | Journal of Materials Research and Technology |
| spelling | doaj-art-102a3bbfea3e46ea8b68c633d40177832025-08-20T03:46:38ZengElsevierJournal of Materials Research and Technology2238-78542025-07-013753754810.1016/j.jmrt.2025.06.033Optimization of the plasma electrolytic oxidation process parameters on 7075 aluminum alloy using Taguchi methodErfan Pirhadi Nouri0Saeed Reza Allahkaram1Mehrnaz Gharagozlou2Mechanically Assisted Corrosion Lab. (MACL), School of Metallurgy and Materials Engineering, College of Engineering, University of Tehran, Tehran, IranSchool of Metallurgy and Materials Engineering, College of Engineering, University of Tehran, Tehran, Iran; Corresponding author.Department of Nanomaterials and Nanocoatings, Institute for Color Science and Technology, Iran; Corresponding author.In this study, the objective was to enhance the corrosion resistance of plasma electrolytic oxidation (PEO) coatings on AA7075 alloy by optimizing the PEO process parameters including current density, time, frequency, and duty cycle, using the Taguchi design of experiments method. The optimal values for these parameters were determined to be 40 A/dm2, 15 min, 1500 Hz, and 30 %, respectively. The influence of each parameter was also discussed, and it was found that the duty cycle was the most significant parameter influencing the corrosion resistance of the PEO coatings. The polarization resistance of the optimized coating reached 105.206 MΩ cm2, which was 49 times higher than the substrate. This improvement indicates an enhanced barrier effect against corrosive agents, suggesting the potential of the optimized PEO coating for use in demanding industrial environments such as aerospace and marine applications. The results of electrochemical impedance spectroscopy (EIS) also indicated an improvement in corrosion resistance. The microstructure and surface morphology of the optimized coating were examined using scanning electron microscopy (SEM) equipped with energy-dispersive X-ray spectroscopy (EDS), which revealed a typical structure of PEO coatings. The porosity of the coating was 3.95 % and the average diameter of micropores was 1.57 μm. The constituent elements of the coating were aluminum, oxygen, silicon, magnesium, and zinc. Additionally, the coating exhibited good adhesion to the substrate, and the thickness of the optimized coating was 9.4 μm. X-ray diffraction (XRD) analysis revealed that the main phases of the coating were gamma-alumina and magnesium oxide.http://www.sciencedirect.com/science/article/pii/S2238785425014553PEOAA7075TaguchiDesign of experimentsCorrosionOptimization |
| spellingShingle | Erfan Pirhadi Nouri Saeed Reza Allahkaram Mehrnaz Gharagozlou Optimization of the plasma electrolytic oxidation process parameters on 7075 aluminum alloy using Taguchi method Journal of Materials Research and Technology PEO AA7075 Taguchi Design of experiments Corrosion Optimization |
| title | Optimization of the plasma electrolytic oxidation process parameters on 7075 aluminum alloy using Taguchi method |
| title_full | Optimization of the plasma electrolytic oxidation process parameters on 7075 aluminum alloy using Taguchi method |
| title_fullStr | Optimization of the plasma electrolytic oxidation process parameters on 7075 aluminum alloy using Taguchi method |
| title_full_unstemmed | Optimization of the plasma electrolytic oxidation process parameters on 7075 aluminum alloy using Taguchi method |
| title_short | Optimization of the plasma electrolytic oxidation process parameters on 7075 aluminum alloy using Taguchi method |
| title_sort | optimization of the plasma electrolytic oxidation process parameters on 7075 aluminum alloy using taguchi method |
| topic | PEO AA7075 Taguchi Design of experiments Corrosion Optimization |
| url | http://www.sciencedirect.com/science/article/pii/S2238785425014553 |
| work_keys_str_mv | AT erfanpirhadinouri optimizationoftheplasmaelectrolyticoxidationprocessparameterson7075aluminumalloyusingtaguchimethod AT saeedrezaallahkaram optimizationoftheplasmaelectrolyticoxidationprocessparameterson7075aluminumalloyusingtaguchimethod AT mehrnazgharagozlou optimizationoftheplasmaelectrolyticoxidationprocessparameterson7075aluminumalloyusingtaguchimethod |