Species separation during coating growth on aluminium by spark anodizing

The mechanism of coating growth during sparking anodizing of aluminium is probed by use of an electrolyte containing both silicate and phosphate ions, with subsequent determination of the locations of silicon and phosphorus species through the coating thickness. Importantly, the main alumina-based layer of the coating contains incorporated silicon and phosphorus species of differing distributions. Phosphorus species are primarily found in a region next to the metal, representing roughly about 30% of the layer thickness. Silicon species are located mainly above this region to the layer surface. New coating material is added in discreet amounts associated with breakdown events, which provide short-circuit paths through the layer. The growth processes within the discharge region result in separation of the silicate- and phosphate-derived species, which may relate to their different mobilities, dependent upon factors such as charge, size and bonding with other species. Further, silicon-rich material is deposited at the surface of the alumina-based layer, which is often encountered in spark anodizing in silicate electrolyte.