The growth kinetics mechanism of microarc oxidation (MAO) coatings on Ti6Al4V alloy was studied by designing a binary mixed electrolyte with various SiO3 2- and B4O7 2- ion ratios via scanning electron microscopy, transmission electron microscopy, X-ray diffraction, X-ray photoelectron spectroscopy, and potentiodynamic polarization. When the ratio of B4O7 2- in the electrolyte is 100%, B4O7 2- dissolves molten TiO2 at a high temperature, exposing nano-scale filamentary channels in the barrier layer of MAO coating, resulting in the repeated nucleation of microarc in the same area. When the ratio of SiO3 2- in the binary mixed electrolyte reaches 10%, the amorphous SiO2 formed by SiO3 2- at high temperatures from discharge blocks discharge channels and induces microarc nucleation in other regions, thus inhabiting the discharge cascade phenomenon. When the ratio of SiO3 2- in the binary mixed electrolyte increases from 15% to 50%, the amounts of molten oxides cover some of the pores formed by the primary microarc discharge, so part of the secondary discharge preferentially generates in the uncovered pores. Finally, the discharge cascade phenomenon occurs. Moreover, the thickness of the MAO coating obtained in the binary mixed electrolyte containing B4O7 2- and SiO3 2- shows a power function with time.
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