Soft plasma electrolysis with complex ions for optimizing electrochemical performance

Insight into the Discriminative Efficiencies and Mechanisms of Peroxy Activation via Fe/Cu Bimetallic Catalysts for Wastewater Purification

Fe/Cu bimetallic catalysts have a synergistic effect that can effectively enhance catalytic activity, so Fe/Cu bimetallic catalysts have been extensively studied. However, the efficacy and mechanisms of Fe/Cu bimetallic catalysts' peroxidation activation have rarely been explored. In this study, Fe/Cu bimetallic materials were fabricated to catalyze different oxidizing agents, including peroxymonosulfate (PMS), peroxydisulfate (PDS), peroxyacetic acid (PAA), and hydrogen peroxide (H2O2), for the degradation of sulfamethoxazole (SMX). The Fe/Cu/oxidant systems exhibited an excellent degradation efficiency of sulfamethoxazole (SMX). In the Fe/Cu/PMS, Fe/Cu/PDS, and Fe/Cu/PAA systems, the main reactive oxygen species (ROS) responsible for SMX degradation were hydroxyl radical (•OH) and singlet oxygen (1O2), while the main ROS was only •OH in the H2O2 system. The differences in the surface structure of the materials before and after oxidation were examined, revealing the presence of a large amount of flocculent material on the surface of the oxidized PMS material. Anion experiments and actual body experiments also revealed that the PMS system had a strong anti-interference ability. Finally, a comprehensive comparison concluded that the PMS system was the optimal system among the four oxidation systems. Overall, this work revealed that the PMS oxidant has a better catalytic degradation of SMX compared to other oxidizers for Fe/Cu, that PMS generates more ROS, and that the PMS system has a stronger resistance to interference.

Study of Coating Growth Direction of 6061 Aluminum Alloy in Soft Spark Discharge of Plasma Electrolytic Oxidation

Conventional plasma electrolytic oxidation treatments produce oxide coatings with micron-scale discharge pores, resulting in insulation and wear and corrosion resistance far below that expected of highly dense Al2O3 coatings. The introduction of cathodic polarization during the plasma electrolytic oxidation process, especially when the applied cathode-to-anode current ratio (Rpn) is greater than 1, triggers a unique plasma discharge phenomenon known as "soft sparking". The soft spark discharge mode significantly improves the densification of the anode ceramic layer and facilitates the formation of the high-temperature α-Al2O3 phase within the coating. Although the soft spark discharge phenomenon has been known for a long time, the growth behavior of the coating under its discharge mode still needs to be studied and improved. In this paper, the growth behavior of the coating before and after soft spark discharge is investigated with the help of the micro-morphology, phase composition and element distribution of a homemade fixture. The results show that the ceramic layer grows mainly along the oxide-electrolyte direction before the soft spark discharge transformation; after the soft spark discharge, the ceramic layer grows along the oxide-substrate direction. It was also unexpectedly found that, under soft spark discharge, the silicon element only exists on the outside of the coating, which is caused by the large size and slow migration of SiO32-, which can only enter the ceramic layer and participate in the reaction through the discharge channel generated by the strong discharge. In addition, it was also found that the relative phase content of α-Al2O3 in the coating increased from 0.487 to 0.634 after 10 min of rotary spark discharge, which is an increase of 30.2% compared with that before the soft spark discharge transition. On the other hand, the relative phase content of α-Al2O3 in the coating decreased from 0.487 to 0.313 after 20 min of transfer spark discharge, which was a 55.6% decrease compared to that before the soft spark discharge transformation.

Study of Anticorrosion and Antifouling Properties of a Cu-Doped TiO2 Coating Fabricated via Micro-Arc Oxidation

As a promising material for petroleum industrial applications, titanium (Ti) and its alloys receive wide attention due to their outstanding physicochemical properties. However, the harsh industrial environment requires an antifouling surface with a desired corrosion resistance for Ti and its alloys. In order to achieve the desired antifouling properties, micro-arc oxidation (MAO) was used to prepare a Cu-doped TiO2 coating. The microstructure of the Cu-doped TiO2 coating was investigated by TF-XRD, SEM, and other characterization techniques, and its antifouling and anticorrosion properties were also tested. The results show the effects of the incorporation of Cu (~1.73 wt.%) into TiO2 to form a Cu-doped TiO2, namely, a Ti-Cu coating. The porosity (~4.8%) and average pore size (~0.42 μm) of the Ti-Cu coating are smaller than the porosity (~5.6%) and average pore size (~0.66 μm) of Ti-blank coating. In addition, there is a significant reduction in the amount of SRB adhesion on the Ti-Cu coating compared to the Ti-blank coating under the same conditions, while there is little difference in corrosion resistance between the two coatings. There, the addition of copper helps to improve the fouling resistance of TiO2 coatings without compromising their corrosion resistance. Our work provides a practical method to improve the antifouling function of metallic Ti substrates, which could promote the application of Ti in the petroleum industry.

Effect of Ultrasonic Frequency on Structure and Corrosion Properties of Coating Formed on Magnesium Alloy via Plasma Electrolytic Oxidation

This study explores the application of ultrasonic vibration during plasma electrolytic oxidation (PEO) to enhance the corrosion resistance of magnesium (Mg) alloy. To this end, three different ultrasonic frequencies of 0, 40, and 135 kHz were utilized during PEO. In the presence of ultrasonic waves, the formation of a uniform and dense oxide layer on Mg alloys is facilitated. This is achieved through plasma softening, acoustic streaming, and improved mass transport for successful deposition and continuous reforming of the oxide layer. The oxide layer exhibits superior protective properties against corrosive environments due to the increase in compactness. Increasing ultrasonic frequency from 40 to 135 kHz, however, suppresses the optimum growth of the oxide layer due to the occurrence of super-soft plasma swarms, which results in a low coating thickness. The integration of ultrasonic vibration with PEO presents a promising avenue for practical implementation in industries seeking to enhance the corrosion protection of Mg alloys, manipulating microstructures and composition.

Synchronized Improvements in the Protective and Bioactive Properties of Plasma-Electrolyzed Layers via Cellulose Microcrystalline

This study reports synchronized improvements in the protective and bioactive properties of Ti-6Al-4V alloy through the formation of titania-based inorganic layers by considering the role of cellulose microcrystalline (CMC) additive into account. Acetate-phosphate-based electrolyte with cellulose CMC is formulated for the first time to modify the porous structure of the oxide layers made via plasma electrolysis of Ti-6Al-4V alloy. The presence of CMC (0, 1, 2, 3 g/L) changed the characteristics of plasma discharges where porous oxide layers with different pore sizes and surface roughness were obtained. A rough oxide layer with large pores was found in the 3 g/L CMC, while a slightly smoother oxide layer with smaller pores was obtained in the case of 2 g/L CMC. The -OH groups in CMC would facilitate the formation of an adsorption layer on the substrate surface, affecting the sparking behavior during plasma electrolysis (PE). Due to a synergy between controlled microstructure, surface roughness, and the insertion of bioactive phases, the coated samples in CMC-containing electrolytes displayed protective and bioactive properties simultaneously. Based on the obtained results, the samples coated in CMC-containing electrolytes can be used as safe implants to replace missing teeth in dental applications.

Graphene shell-encapsulated copper-based nanoparticles (G@Cu-NPs) effectively activate peracetic acid for elimination of sulfamethazine in water under neutral condition

In this study, a graphene shell-encapsulated copper-based nanoparticles (G@Cu-NPs) was prepared and employed for peracetic acid (PAA) activation. The characterization of G@Cu-NPs confirmed that the as-prepared material was composed of Cu⁰ and Cu₂O inside and encapsulated by a graphene shell. Experimental results suggested that the synthesized G@Cu-NPs could activate PAA to generate free radicals for efficiently removing sulfamethazine (SMT) under neutral condition. The formation of graphene shells could strongly facilitated electron transfer from the core to the surface. Radical quenching experiments and electron spin resonance (ESR) analysis confirmed that organic radicals (R-O•) and hydroxyl radicals (•OH) were generated in the G@Cu-NPs/PAA system, and R-O• (including CH₃CO₃• and CH₃CO₂•) was the main contributor to the elimination of SMT. The possible SMT degradation pathways and mechanisms were proposed, and the toxicity of SMT and its intermediates was predicted with the quantitative structure-activity relationship (QSAR) analysis. Besides, the effects of some key parameters, common anions, and humic acid (HA) on the removal of SMT in the G@Cu-NPs/PAA system were also investigated. Finally, the applicability of G@Cu-NPs/PAA system was explored, showing that the G@Cu-NPs/PAA system possessed satisfactory adaptability to treat different water bodies with admirable reusability and stability.

Improving Corrosion and Photocatalytic Properties of Composite Oxide Layer Fabricated by Plasma Electrolytic Oxidation with NaAlO2

The present work dealt with the development of a protective and functional oxide layer via one-step plasma electrolytic oxidation (PEO) on pure titanium by employing highly concentrated aluminate solution in a short processing time. A compositional analysis showed that Al₂TiO₅ active compound was formed successfully by means of Al₂O₃ incorporation when TiO₂ was spontaneously developed with the aid of plasma swarms. The electrochemical performance showed the protective and functional capabilities of the layer, which was attributed to the respective amounts of Al₂O₃ and Al₂TiO₅. Such capabilities were achieved in a short processing time, thus reducing the total production cost.

Microstructure and Properties in Simulated Seawater of Copper-Doped Micro-arc Coatings on TC4 Alloy

Micro-arc oxidation (MAO) ceramic coatings were prepared on TC4 titanium alloys by adding CuSO4 to a (NaPO3)6 base solution. The microstructures of the MAO coatings were characterized by scanning electron microscopy (SEM), energy dispersive (EDS), and X-ray photoelectron spectroscopy (XPS). The corrosion resistance and wear resistance of these coatings were evaluated via hydrochloric acid immersion of weight deficit and friction tests. Those results indicated the presence of Cu in the MAO coating in the form of CuO and Cu2O. Incorporation of CuSO4 results in a thickness and roughness increase in the coating. The coating has a lower coefficient of friction (0.2) upon the addition of 4 g/L of CuSO4. The antibacterial properties of the MAO coatings were maximized at 6 g/L of CuSO4. However, the corrosion resistance of the copper-doped MAO coating did not exceed the undoped coating. This study shows that the addition of CuSO4 to the electrolyte successfully prepared copper-containing micro-arc oxidation coatings, which improved the wear resistance and antibacterial properties of the coating.

Degradation of sulfamethazine in water by sulfite activated with zero-valent Fe-Cu bimetallic nanoparticles

In this work, zero-valent Fe-Cu bimetallic nanoparticles were synthesized using a facile method, and applied to activate sulfite for the degradation of sulfamethazine (SMT) from the aqueous solution. The key factors influencing SMT degradation were investigated, namely the theoretical loading of Cu, Fe-Cu catalyst dosage, sulfite concentration and initial solution pH. The experimental results showed that the Fe-Cu/sulfite system exhibited a much better performance in SMT degradation than the bare Fe⁰/sulfite system. The mechanism and possible degradation pathway of SMT in Fe-Cu/sulfite system were revealed. The reactive radicals that played a dominant role in the SMT degradation process were •OH and SO₄^•-, while the loading of Cu induced the synergistic effect between Fe and Cu. The redox cycle between Cu(I)/Cu(II) remarkably contributed to the conversion of Fe(III) to Fe(II), greatly enhancing the catalytic performance of Fe-Cu bimetal. In real groundwater applications, the Fe-Cu/sulfite system also exhibited satisfactory SMT degradation. The 30-day aging tests of Fe-Cu particles demonstrated that the aging of catalyst was not obviously affecting the removal of SMT. Furthermore, the reusability of catalyst was evidenced by the recycling experiments. This study provides a promising application of bimetal activated sulfite for enhanced contaminant degradation in groundwater.

Addition of Organic Acids during PEO of Titanium in Alkaline Solution

This research study describes recent advances in understanding the effects of the addition of organic acids, such as acetic, lactic, citric and phytic acids, on the process of plasma electrolytic oxidation (PEO) on Ti using an alkaline bath. As the plasma developed over the workpiece is central to determine the particular morphological and structural features of the growing oxide, the focus is then on the inter-relationships between the electrolyte and the resultant plasma regime established. In situ optical emission spectroscopy (OES) allowed us to verify a marked plasma suppression when adding low-molecular-weight anions such as acetates, resulting in short-lived and well-distributed discharges. Conversely, when more bulky anions, such as lactates, citrates and phytates, were considered, a less efficient shielding of the electrode caused the build-up of long-lasting and destructive sparks responsible for the formation of thicker coatings, even >30 µm, at the expense of a higher roughness and loss of compactness. Corrosion resistance was tested electrochemically, according to electrochemical impedance spectroscopy (EIS), and weight losses evidenced the coatings produced in the solution containing acetates to be more suitable for service in H2SO4.

Construction of multi-layered Zn-modified TiO2 coating by ultrasound-auxiliary micro-arc oxidation: Microstructure and biological property

Surfaces with desirable cytocompatibility and bactericidal ability are favoured for orthopaedic implants to stimulate osteogenic activity and to prevent implant-associated infection. In this work, we creatively introduce ultrasonic vibration (UV) to micro-arc oxidation (MAO) process and explore its influence on the microstructure, corrosion property and biological responses of Zn-modified TiO₂ coating. With the introduction of UV, a uniform surface layer with homogeneously-distributed clusters could be produced as the outer layer, which possesses a fusion band with the underlying TiO₂. The microstructural modification associated with UV results in the enhanced corrosion resistance, increased adhesive strength and improved biological performances of the resultant coating relative to that with the absence of UV. Hence, the ultrasonic auxiliary micro-arc oxidation (UMAO) is regarded as a promising surface modification method to produce Ti-based orthopaedic implants of high quality.

Electrochemically Stable and Catalytically Active Coatings Based on Self-Assembly of Protein-Inorganic Nanoflowers on Plasma-Electrolyzed Platform

Despite the growing research on biomolecule-inorganic nanoflowers for multiple applications, it remains challenging to control their development on stationary platforms for potential portable and wearable devices. In this work, the self-assembly of Cu₃(PO₄)₂-bovine serum albumin hybrid nanoflowers is facilitated by an alumina platform whose surface is tailored by wet plasma electrolysis. This allows an interlocking of hybrid nanoflowers with the surface motifs of the solid platform, resulting in a hierarchy similar to nanocarnation (NC) petals on an inorganic bed. Density functional theory calculations are performed to reveal the primary bonding mode between the organic and inorganic components and to identify the active sites of the protein structure in order to provide mechanistic insights that can explain self-assembly of NCs overall. The hybrid architecture displays an adaptive microstructure in different aqueous environment, giving rise to a dual-function based on its electrochemical stability and catalytic activity toward radical degradation of organic pollutant.

Hybrid Organic-Inorganic Materials on Metallic Surfaces: Fabrication and Electrochemical Performance

In recent years, hybrid organic-inorganic (HOI) materials have attracted massive attention as they combine the unique properties of organic and inorganic compounds. In this review, we focus on the formation of HOI materials and their electrochemical performance that can be controlled by microstructural design depending upon their chemical composition. This overview outlines the recent strategies of preparing HOI materials on metallic surface via wet-electrochemical systems, such as plasma electrolysis (PE) and dip chemical coating (DCC). The corresponding electrochemical behavior for short and long term exposures is also summarized.

The Potential of Calcium/Phosphate Containing MAO Implanted in Bone Tissue Regeneration and Biological Characteristics

Micro arc oxidation (MAO) is a prominent surface treatment to form bioceramic coating layers with beneficial physical, chemical, and biological properties on the metal substrates for biomaterial applications. In this study, MAO treatment has been performed to modify the surface characteristics of AZ31 Mg alloy to enhance the biocompatibility and corrosion resistance for implant applications by using an electrolytic mixture of Ca₃(PO₄)₂ and C₁₀H₁₆N₂O₈ (EDTA) in the solutions. For this purpose, the calcium phosphate (Ca-P) containing thin film was successfully fabricated on the surface of the implant material. After in-vivo implantation into the rabbit bone for four weeks, the apparent growth of soft tissues and bone healing effects have been documented. The morphology, microstructure, chemical composition, and phase structures of the coating were identified by SEM, XPS, and XRD. The corrosion resistance of the coating was analyzed by polarization and salt spray test. The coatings consist of Ca-P compounds continuously have proliferation activity and show better corrosion resistance and lower roughness in comparison to mere MAO coated AZ31. The corrosion current density decreased to approximately 2.81 × 10^-7 A/cm² and roughness was reduced to 0.622 μm. Thus, based on the results, it was anticipated that the development of degradable materials and implants would be feasible using this method. This study aims to fabricate MAO coatings for orthopedic magnesium implants that can enhance bioactivity, biocompatibility, and prevent additional surgery and implant-related infections to be used in clinical applications.

Optimization of Surface Properties of Plasma Electrolytic Oxidation Coating by Organic Additives: A Review

Plasma electrolytic oxidation (PEO) is an effective surface modification method for producing ceramic oxide layers on metals and their alloys. Although inorganic electrolytes are widely used in PEO, the organic additives have received considerable interest in the last decade due to their roles in improving the final voltage and controlling spark discharging, which lead to significant improvements in the performance of the obtained coatings. Therefore, this review summarized recent progress in the impacts of organic additives on the electrical response and the plasma discharges behavior during the PEO process. The detailed influence of organic additives, namely alcohols, organic acids, organic amines, organic acid salts, carbohydrate compounds, and surfactants on the corrosion behavior of PEO coatings is outlined. Finally, the future aspects and challenges that limit the industrial applications of PEO coating made in organic electrolytes are also highlighted.

Effects of the sources of calcium and phosphorus on the structural and functional properties of ceramic coatings on titanium dental implants produced by plasma electrolytic oxidation

Plasma Electrolytic Oxidation (PEO) is as a promising technique to modify metal surfaces by application of oxide ceramic coatings with appropriate physical, chemical and biological characteristics. Therefore, objective of this research was to find the simplest settings, yet able to produce relevant bioactive implant surfaces layers on Ti implants by means of PEO. We show that an electrolyte containing potassium dihydrogen phosphate as a source of P and either calcium hydroxide or calcium formate as a source of Ca in combination with a chelating agent, ethylenediamine tetraacetic acid (EDTA), is suitable for PEO to deliver coatings with desired properties. We determined surface morphology, roughness, wettability, chemical and phase composition of titanium after the PEO process. To investigate biocompatibility and bacterial properties of the PEO oxide coatings we used microbial and cell culture tests. The electrolyte based on Ca(OH)₂ and EDTA promotes active crystallization of apatites after PEO processing of the Ti implants. The PEO layers can increase electrochemical corrosion resistance. The PEO can be potentially used for development of bioactive surfaces with increased support of eukaryotic cells while inhibiting attachment and growth of bacteria without use of antibacterial agents.

Influence of Cu2+ Ions on the Corrosion Resistance of AZ31 Magnesium Alloy with Microarc Oxidation

The objectives of this study were to reduce the corrosion rate and increase the cytocompatibility of AZ31 Mg alloy. Two coatings were considered. One coating contained MgO (MAO/AZ31). The other coating contained Cu²⁺ (Cu/MAO/AZ31), and it was produced on the AZ31 Mg alloy via microarc oxidation (MAO). Coating characterization was conducted using a set of methods, including scanning electron microscopy, energy-dispersive spectrometry, X-ray photoelectron spectroscopy, and X-ray diffraction. Corrosion properties were investigated through an electrochemical test, and a H₂ evolution measurement. The AZ31 Mg alloy with the Cu²⁺-containing coating showed an improved and more stable corrosion resistance compared with the MgO-containing coating and AZ31 Mg alloy specimen. Cell morphology observation and cytotoxicity test via Cell Counting Kit-8 assay showed that the Cu²⁺-containing coating enhanced the proliferation of L-929 cells and did not induce a toxic effect, thus resulting in excellent cytocompatibility and biological activity. In summary, adding Cu ions to MAO coating improved the corrosion resistance and cytocompatibility of the coating.

Decoration of an inorganic layer with nickel (hydr)oxide via green plasma electrolysis

In this study, we describe the green plasma electrolysis of a magnesium alloy in alkaline electrolyte to produce a hybrid inorganic layer with nickel (hydr)oxide incorporated in a matrix of magnesium oxide, and investigate the electrochemical and optical properties of this material. The addition of Ni(NO₃)₂·6H₂O to the electrolyte reduced the size of the micro-defects found in the inorganic layer after plasma electrolysis by inducing soft plasma discharges. As a result, through cyclic voltammetry and polarization tests, the corrosion stability of the sample containing nickel (hydr)oxide was significantly enhanced. Measurement of the optical properties reveals that the material possesses excellent energy efficiency as indicated by a high solar absorptivity of ∼0.92 and a low infrared emissivity of ∼0.13 which are presumably due to the inherent dark-brown colour of nickel (hydr)oxide. We expect that these results will have implications in the development of functional materials with excellent optical and corrosion properties by considering green processing utilizing alkaline electrolyte.

Nickel (hydr)oxide decorating MgO matrix via green plasma electrolysis exhibited high solar absorbance but low infrared emissivity.

The Role of Cathodic Current in Plasma Electrolytic Oxidation of Aluminum: Phenomenological Concepts of the "Soft Sparking" Mode

A comprehensive analysis of experimental data relating to so-called "soft sparking" mode of plasma electrolytic oxidation (PEO) has been undertaken. The transition to the soft sparking mode is accompanied by a number of characteristic effects, such as a decrease in anodic voltage, acoustic and light emission, increase in hysteresis in transient current-voltage curves, improved uniformity of the discharge distribution on the surface, disappearance of atomic lines, and development of continuous radiation in the optical emission spectra. An explanation of the main features of PEO process operated under soft sparking conditions is proposed assuming the existence of a specific narrow region in the coating thickness, where the main anodic voltage drops. Because of high electric field in this "active zone", both anodic oxidation of the metal substrate and high-energy processes may take place. According to this assertion, the soft sparking mode of PEO is caused by cathodic polarization (a) eliminating the potential barrier at the oxide-electrolyte interface due to local acidification and (b) increasing electric field at the metal-oxide interface during subsequent anodic half-cycle due to narrowing of low-conductive part within the active zone. Based on this consideration, it is possible to account for the main characteristic phenomena accompanying the PEO process on aluminum under alternating polarization.

Electron-Donor and -Acceptor Agents Responsible for Surface Modification Optimizing Electrochemical Performance

The electrochemical roles of electron-donor and -acceptor agents in surface reforming of magnesium alloy were investigated via plasma electrolysis. The surface modification was performed in an aluminate-based electrolyte, having urea and hydrazine with inherent molecular structures, which might act as electron acceptor and donor during plasma-assisted electrochemical reaction. The presence of hydrazine working as donor would promote the formation of magnesium aluminates in the oxide layer, resulting in superior compactness of the oxide layer to that when urea was used as the working as acceptor since the precipitation of MgCO₃ was favored in the electrolyte with urea. The thickness of the oxide layer formed by a combination of urea and hydrazine was higher than urea, while the porosity was higher than hydrazine. The electrochemical performance was enhanced in the order of hydrazine, urea and hydrazine combined, and urea, which was discussed on the basis of impedance interpretation.

Toward a nearly defect-free coating via high-energy plasma sparks

A nearly defect-free metal-oxide-based coating structure was made on Al-Mg-Si alloy by plasma electrolytic oxidation at high current density accompanying high-energy plasma sparks. The present coatings were performed at two different current densities of 50 and 125 mA/cm² in the alkaline-phosphate-based electrolytes with different concentrations of sodium hexafluoroaluminate (Na₃AlF₆). The addition of (Na₃AlF₆) to the electrolyte used in this study would result in a decrease in the size of the micropore, and a reasonably defect-free coating structure was achieved in the sample treated at high current density of 125 mA/cm². This was attributed mainly to the hydrolysis of AlF₆³⁻ triggered by intense plasma sparks, which resulted in a uniform distribution of fluorine throughout the coating. Accordingly, the corrosion performance of the coating formed in the electrolyte containing 1.5 g/L Na₃AlF₆ at 125 mA/cm² was improved significantly as confirmed by electrochemical impedance analysis. In addition, the formation mechanism of the nearly defect-free coating in the presence of Na₃AlF₆ was discussed.