Improved wear and corrosion resistance of alumina alloy by MAO and PECVD

Aluminum alloys, which are vital in various industries, are susceptible to corrosion and wear. Although the micro-arc oxidation (MAO) method addresses these issues, it introduces microporosity, which undermines the integrity of the alloy. In this study, MAO coatings are enriched via plasma-enhanced chemical vapor deposition (PECVD) using hexamethyldisilane, specifically SiCOx and SiOx. The assessment of the mechanical, tribological, and corrosion-resistant characteristics of these composite coatings reveals substantial enhancements in the aluminum alloy properties post-PECVD treatment. Surface morphology observations highlight the reduced pore size and area of the PECVD-coated surfaces, particularly in SiCOx coatings, which are known for their superior gap-filling properties. Scratch tests demonstrate superior adhesion of SiCOx coatings, showed a higher scratch resistance of approximately 17.8 N compared to 15.9 N for SiOx coatings. The wear rate of the SiCOx coating significantly decreased compared to the MAO coating owing to higher hardness, dropping from 3.57 × 10 −5  mm 3 /N·m to 2.04 × 10 −5  mm 3 /N·m. SiCOx-coated surfaces show higher corrosion potential (−0.0078  V ) than MAO-only coating (−0.0212 V), indicating enhanced corrosion resistance. These innovative coatings provide an advanced surface treatment strategy and are suitable for a wide range of industrial applications owing to their enhanced surface attributes.