Effect of Y2O3 rare earth oxide on the microstructure and growth kinetics of TiO2-based ceramic coatings fabricated by micro arc oxidation

This study investigates the influence of Y2O3 addition on the microstructure, growth kinetics, and mechanical properties of TiO2-based ceramic coatings formed on Ti–6Al–4V alloy through the Micro Arc Oxidation (MAO) process. The experiments were carried out using Ti–6Al–4V plates coated in silicate-based electrolytes, with and without 1 g/L Y2O3, under a constant current density of 5 A/dm2 and a voltage of 360 ± 20 V for different treatment times (1, 3, 7, and 10 min). The coatings were evaluated by weight gain measurements, SEM/EDS analyses, X-ray diffraction (XRD), and constant load scratch testing supported by profilometry. Results revealed that Y2O3 significantly accelerated coating growth during the initial stages, leading to higher weight gains and denser, less porous morphologies compared to Y2O3-free coatings. XRD analysis indicated amorphous TiO2 and anatase phases at short durations, while rutile formation became dominant with longer treatments. Kinetic modeling demonstrated that both coatings initially followed a linear reaction-controlled mechanism (n ≈ 1), with calculated growth constants of 3.44 × 10⁻4 mg/mm2·s for Ti-MAO and 7.45 × 10⁻4 mg/mm2 s for Ti–Y2O3–MAO. However, after approximately 420 s, the Y2O3 coatings exhibited a marked reduction in growth rate due to electrical insulation effects of the thickened ceramic layer, resulting in multi-stage kinetics. Constant load scratch testing showed that Y2O3 incorporation reduced groove depth and width by nearly 45%, improving adhesion strength and mechanical durability. These findings confirm that rare-earth oxide addition is an effective strategy for enhancing the performance of MAO coatings on titanium alloys.