Microstructure and Properties of Composite Ceramic Film Containing ZrO₂ Prepared by Micro-Arc Oxidation on Aluminum Surface

A four-factor and three-level orthogonal test scheme was designed to prepare composite ceramic film containing ZrO₂ on the surface of 1060 aluminum, using positive voltage, concentrations of Na₂SiO₃, NaOH and ZrO₂ as the main parameters of micro-arc oxidation. The surface morphology of the film was analyzed by scanning electron microscopy (SEM); the phase composition of the film was analyzed by X-ray diffraction (XRD); the surface roughness and the thickness were tested by roughness meter and optical microscopy (OM) respectively; and bonding force between the film and the substrate was tested by coating adhesion tester. The results show that the positive voltage had relatively large effects on the roughness and thickness of the film; the Na₂SiO₃ concentration had a relatively large influence on the bonding force between the film and the substrate. ZrO₂ particles could help to increase the density of the film, reduce the number and size of pores in the film, and improve its corrosion resistance.