Characterization of Al2O3 coatings oxidized from Al with different proportion of seed crystals at a lower temperature

Al layer with α-Al2O3 seed crystals was prepared on the surface of 316L stainless steel (SS) by a double cathodes discharge technique, in which the mixed targets of pure Al doped with different proportions of α-Al2O3 were used. Then, Al2O3 coatings were obtained after plasma oxidization at 580 °C. The phase composition, microstructure and morphology of the coatings were studied respectively by means of glancing-angle (1°) X-ray diffractometry (GAXRD) and scanning electron microscopy (SEM). Furthermore, the bonding force and corrosion resistance of the coatings were measured. The results indicated that α-Al2O3 nucleated and grew surrounding the seed crystals as the Volmer–Weber Mode. The Al2O3 coating was compact, performing a good corrosion resistance and metallurgical bonding. The inducing effects of α-Al2O3 with different fractions were discussed. α-Al2O3 (5.5 wt.%) was distributed in the Al layer when the target possessing 10% α-Al2O3 was used. After plasma oxidation, 65.54 wt.% α-Al2O3 was obtained which was 10.34% more than that obtained by the oxidation of pure Al at the same condition. However, the inducing effects became weak with the further increment of content of α-Al2O3 seed crystals.