Research Progress of Micro-arc Oxidation on Titanium Alloy Surface and its Wear-resistant and Insulating Strengthening Strategies

HUANG Jianchao; SONG Kaiqiang; WU Hulin; PENG Dong; BAI Yixin; WANG Xuan; ZHANG Min; HE Qingbing; LI Li; CONG Dalong; LI Zhongsheng

doi:10.16490/j.cnki.issn.1001-3660.2026.07.016

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Surface Technology ›› 2026, Vol. 55 ›› Issue (7) : 201-218. DOI: 10.16490/j.cnki.issn.1001-3660.2026.07.016

Research Progress of Micro-arc Oxidation on Titanium Alloy Surface and its Wear-resistant and Insulating Strengthening Strategies

HUANG Jianchao, SONG Kaiqiang, WU Hulin, PENG Dong, BAI Yixin, WANG Xuan, ZHANG Min, HE Qingbing, LI Li, CONG Dalong^*, LI Zhongsheng^*

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Abstract

Titanium alloy is extensively utilized in aerospace, marine engineering and other high-tech fields due to its excellent specific strength, thermal stability and corrosion resistance. However, its inherent low shear resistance and limited work-hardening capacity usually result in inadequate wear resistance, while its insufficient insulation performance caused by conductivity also limits its service performance under extreme conditions. Micro-arc oxidation (MAO), as a surface modification technology for in-situ growth of ceramic coatings, has become an effective method to improve the wear-resistance and insulation properties of titanium alloy surfaces. Its advantages include excellent coating-substrate, broad process adaptability, and environmental sustainability. In this paper, the research progress of MAO technology in wear resistance and insulation strengthening of titanium alloy surfaces is systematically reviewed. The coating growth mechanism, process control, performance design and composite strengthening strategies are discussed in detail. Firstly, the growth mechanism and discharge behavior of MAO ceramic coatings are systematically elucidated. The MAO process typically comprises three sequential stages: initial anodic oxidation, micro-arc discharge breakdown and steady-state deposition. The coating structure usually presents a double-layer feature with a dense inner layer and a porous outer layer. The growth of the coating is not only governed by electrical parameters but also significantly influenced by electrolyte composition and doped particles. In addition, integrating diverse discharge models with advanced characterization techniques provides a theoretical foundation for elucidating the coating formation mechanism. Secondly, the influence of process parameters on ceramic coatings microstructure is systematically analyzed. Among electrical parameters, the frequency and duty cycle synergistically control coating porosity and thickness. Elevated current densities generally accelerate coating growth and facilitate particle incorporation. The voltage application mode (whether constant or stepped) affects phase formation and structural uniformity. Regarding the electrolyte system, silicate-based electrolytes typically promote a porous outer layer, whereas phosphate-based solutions favor a denser inner layer; hybrid electrolytes can optimize both adhesion and wear resistance. Incorporating nanoparticles effectively seals micro-pores, enhances coating densification, and can introduce reinforcing hard phases or solid lubricants, thereby significantly improving coating properties. Additionally, substrate surface morphology and oxidation duration critically affect coating uniformity and final thickness. Design strategies for wear-resistant and insulating MAO coatings primarily encompass three approaches: (1) introducing high-hardness or lubricating composite phases to reduce the friction coefficient and improve the wear resistance; (2) employing hybrid surface engineering techniques to achieve structural optimization and synergistic performance enhancement; and (3) designing coatings with high density and increased thickness to barrier corrosive medium ingress, thereby improving both insulation and corrosion resistance. The performance analysis shows that the hard phases such as rutile TiO₂ and Al₂O₃ formed in the MAO coating can significantly improve the wear resistance, while the coating thickness and crystallinity are directly related to its insulation properties. To further improve coating performance, composite strengthening strategies integrating MAO are developed: (1) pre-treatment (e.g., laser texture, ultrasonic rolling), which can refine grains, induce residual compressive stress, and improve subsequent coating adhesion and density; (2) post-treatment (e.g., low temperature nitriding, anodic oxidation, sol-gel sealing), which can effectively infiltrate and seal inherent micro-pores and cracks, augmenting wear and corrosion resistance; and (3) synergistic in-process methods (e.g., laser, ultrasonic, magnetic field assisted MAO), which optimize discharge uniformity through energy field coupling and promote electrolyte doping and structural densification. Finally, future development of MAO technology is prospected to focus on three key directions: (1) developing energy-efficient, environmentally benign composite coating processes; (2) constructing data-driven and AI-enhanced predictive models for precise process-performance control; and (3) accelerating the industrial application of special functional coatings for extreme working conditions. Through interdisciplinary and industry-academia collaboration, micro-arc oxidation technology is expected to play an irreplaceable role in the field of titanium alloy surface modification.

Key words

titanium alloy / micro-arc oxidation / wear-resistant and insulating / surface coating / discharge behavior

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HUANG Jianchao, SONG Kaiqiang, WU Hulin, PENG Dong, BAI Yixin, WANG Xuan, ZHANG Min, HE Qingbing, LI Li, CONG Dalong, LI Zhongsheng. Research Progress of Micro-arc Oxidation on Titanium Alloy Surface and its Wear-resistant and Insulating Strengthening Strategies[J]. Surface Technology. 2026, 55(7): 201-218

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