Numerical Analysis of Cavitation Erosion in 316L Steel with CrN PVD Coating.

The erosion process of a 4 µm monolayer CrN coating deposited on 316L stainless steel due to cavitation was investigated using finite element analysis (FEA). To estimate load parameters from cavitation pit geometry resulting from high impact velocity and high strain rate, the explicit dynamic solver was employed. Water microjet impacts at velocities of 100, 200 and 500 m/s were simulated to recreate different cavitation erosion intensities observed in the experiment. The resulting damage characteristics were compared to previous studies on uncoated 316L steel. The relationship between impact velocity and postimpact geometry was examined. Simulations revealed that only impact at 500 m/s can exceed the maximum yield stress of the substrate without penetrating the coating. Subsequent impacts on the same zone deepen the impact pit and penetrate the coating, leading to direct substrate degradation. The influence of impact velocity on the coating degradation process is discussed.

Influence of heating temperature and time on mechanical-degradation, microstructures and corrosion performances of Teflon/granite coated aluminum alloys used for non-stick cookware.

This study explores the functional characteristics (erosion, corrosion, mechanical damage, and microstructural features) of non-stick cookware made from aluminum alloys. Typically coated with polytetrafluoroethylene (PTFE-Teflon) or ceramic for non-stick properties, we conducted a systematic investigation using corrosion, abrasion, and mechanical tests on six types of cookware from different manufacturers (Manuf-1-6). The cookware was heated at various temperatures [Room temperature (RT), 100, 175, 250, & 350 °C] and times (45 & 120 min). Tests included Taber wear, Adhesive Pull-off, hot & RT corrosion, and surface roughness measurements. Characterization involved optical microscopy, scanning electron microscope (SEM) with electron backscattered diffraction (EBSD), and x-ray diffraction (XRD). Ceramic-coated cookware from Manuf-4 demonstrated superior mechanical strength, wear, and corrosion resistance due to refined microstructures. Manuf-1's PTFE-coated cookware also performed well. Optimal results were observed when heating below 250 °C for up to 45 min. Prolonged heating and temperatures beyond 250 °C adversely affected internal structures of all cookware. Thus, it is advisable to use Al-based non-stick cookware below 250 °C for a maximum of 45 min.

Extensive Metallosis in a Primary Knee Arthroplasty as a Result of Polyethylene Wear: Is It Avoidable?

Metallosis is known to occur in metal-on-metal arthroplasty and has been of concern to orthopaedic surgeons worldwide. It is a rare, late complication of total knee arthroplasty (TKA), in which metal-on-metal contact leads to metal debris deposition in the surrounding tissue. Reasons for metal-on-metal contact could range from wear of the polyethylene insert to abnormal joint biomechanics. Many components can affect the development of metallosis, with polyethylene wear being the most common cause of metallosis. This paper discusses the case of an 85-year-old man who developed metallosis, attributed to polyethylene wear, 24 years after undergoing TKA. It also highlights the different components of knee prostheses, evaluates the efficacy of different types of polyethylene, and explores whether ceramic coating can improve TKA outcomes and reduce complications such as metallosis.

Shear bond strength between standard or modified zirconia surfaces and two resin cements incorporating or not 10-MDP in their matrix.

OBJECTIVE: This study aimed first to compare the shear bond strength between zirconia samples luted to enamel with a 10-MDP- containing resin cement (Panavia F2.0, Kuraray, Japan) and those luted with a resin cement using a separated 10-MDP monomer-containing bottle (Panavia V5, Kuraray, Japan). The second objective was to evaluate the bond stability after 150 days of aging in water, between enamel and zirconia ceramic surface enhanced with a glass-ceramic coating. MATERIALS AND METHODS: 80 specimens composed of ceramic cylinders and enamel disks were obtained, within eight experimental groups (n = 10). 60 zirconia cylinders (Katana STML zirconia, Kuraray, Japan) were assigned to 3 groups according to their surface treatment: milled/sintered surface (ZRCT), tribochemical silica-coating (Cojet™ Sand, 3 M ESPE, Seefeld, Germany) (ZRTC), and glass-ceramic coating (IPS e.max Zirpress) (ZRZP). 20 cylinders of lithium disilicate had a milled surface (IPS e.max CAD, Ivoclar-Vivadent, Schaan, Liechtenstein) (ECAD). The cylinders of each group were further divided into two subgroups according to the resin cement used: Panavia F2.0 (-PF) and Panavia V5 (-PV). All specimens were stored in distilled water for 150 days before shear bond strength (SBS) tests. The fracture mode was analyzed, and data were statistically computed (two-way ANOVA, post hoc Tukey test, p < 0.05, SPSS, IBM, v26). RESULTS: The ECAD-PF group recorded the highest SBS values (31.75 ± 2.2), and the ZRCT-PF group recorded the lowest values (5.59 ± 1.1). The two-way ANOVA test showed that ceramic surface treatment had a statistically significant effect on SBS (F (3,72) = 38.95, p < 0.001) while the type of ARC did not (F (1,72) = 2.40, p = 0.126). Tukey's post hoc test revealed no statistical difference between the ZRZP and the ZRTC or ECAD groups. CONCLUSION: Within the limitations of this study, the PV resin achieved similar shear bond strength results between tribocoated zirconia and enamel compared to the one for glass-ceramic and enamel. Furthermore, a long-term durable bond, similar to the glass-ceramic one, was achieved with the heat pressed ceramic coated specimens. Thus, this new surface treatment could be recommended for anterior cantilever bridges for its fracture resistance and bonding ability.

Prediction of biological development effects on drag forces of ceramic hull coating using Reynolds-averaged Navier-Stokes-based solver.

Ships in service feature surfaces that exhibit biofouling, which alters the hydrodynamics of the vessels, thus affecting their normal displacement and significantly increasing their fuel consumption. The application of three types of ceramic coatings as ecological, effective and durable alternatives to commercial silicone-based marine coatings is investigated in this study. Three different ceramic glazes and two control commercial paints are analysed in an actual environment during 20 months of exposure to simulate the navigation conditions such that growth and roughness data can be obtained and then applied to computational fluid dynamics (CFD) software using an open-source Reynolds-averaged Navier-Stokes solver. The CFD results are validated under smooth hull conditions with a full-scale Kriso Container Ship (KCS) model and with different levels of hull roughness. The developed approach shows that the drag in hulls coated with conventional paint is 19% greater than that in hulls with ceramic coating.

Glass-Ceramic Coating on Silver Electrode Surface via 3D Printing.

Silver electrodes are commonly used as a conductive layer for electromagnetic devices. It has the advantages of good conductivity, easy processing, and good bonding with a ceramic matrix. However, the low melting point (961 °C) results in a decrease in electrical conductivity and migration of silver ions under an electric field when it works at high temperatures. Using a dense coating layer on the silver surface is a feasible way to effectively prevent the performance fluctuation or failure of the electrodes without sacrificing its wave-transmitting performance. Calcium-magnesium-silicon glass-ceramic (CaMgSi2O6) is a diopside material that has been widely used in electronic packaging materials. However, CaMgSi2O6 glass-ceramics (CMS) are facing tough challenges, such as high sintering temperature and insufficient density after sintering, which significantly confine its applications. In this study, CaO, MgO, B2O3, and SiO2 were used as raw materials to manufacture a uniform glass coating on the silver and Al2O3 ceramics surface via 3D printing technology followed by high-temperature sintering. The dielectric and thermal properties of the glass/ceramic layer prepared with various CaO-MgO-B2O3-SiO2 components were studied, and the protective effect of the glass-ceramic coating on the silver substrate at high temperatures were evaluated. It was found that the viscosity of the paste and the surface density of the coating increase with the increase of solid contents. The 3D-printed coating shows well-bonded interfaces between the Ag layer, the CMS coating, and the Al2O3 substrate. The diffusion depth was 2.5 µm, and no obvious pores and cracks can be detected. According to the high density and well-bonded glass coating, the silver was well protected from the corrosion environment. Increasing the sintering temperature and extending the sintering time is beneficial to form the crystallinity and the densification effect. This study provides an effective method to manufacture a corrosive-resistant coating on an electrically conductive substrate with outstanding dielectric performances.

Surface Modified ß-Ti-18Mo-6Nb-5Ta (wt%) Alloy for Bone Implant Applications: Composite Characterization and Cytocompatibility Assessment.

Commercially available titanium alloys such as Ti-6Al-4V are established in clinical use as load-bearing bone implant materials. However, concerns about the toxic effects of vanadium and aluminum have prompted the development of Al- and V-free ß-Ti alloys. Herein, a new alloy composed of non-toxic elements, namely Ti-18Mo-6Nb-5Ta (wt%), has been fabricated by arc melting. The resulting single ß-phase alloy shows improved mechanical properties (Young's modulus and hardness) and similar corrosion behavior in simulated body fluid when compared with commercial Ti-6Al-4V. To increase the cell proliferation capability of the new biomaterial, the surface of Ti-18Mo-6Nb-5Ta was modified by electrodepositing calcium phosphate (CaP) ceramic layers. Coatings with a Ca/P ratio of 1.47 were obtained at pulse current densities, -jc, of 1.8-8.2 mA/cm2, followed by 48 h of NaOH post-treatment. The thickness of the coatings has been measured by scanning electron microscopy from an ion beam cut, resulting in an average thickness of about 5 µm. Finally, cytocompatibility and cell adhesion have been evaluated using the osteosarcoma cell line Saos-2, demonstrating good biocompatibility and enhanced cell proliferation on the CaP-modified Ti-18Mo-6Nb-5Ta material compared with the bare alloy, even outperforming their CaP-modified Ti-6-Al-4V counterparts.

The Significant Effect of Mechanical Treatment on Ceramic Coating for Biomedical Application.

Titanium and its alloys are commonly preferred materials used for biomedical implants. However, these alloys have issues related to corrosion resistance as a result of the aggressive attack of human body fluids. Several researchers have attempted to produce a ceramic coating via physical vapour deposition (PVD). A PVD layer consists of pores, pinholes, and columnar growth that attack the substrate as an aggressive medium. The aim of this research is to evaluate the influence of ultrasonic vibration parameters on a TiN-coated biomedical Ti-13Zr-13Nb alloy. This study used TiN to formulate and coat disk-type samples in a fixed condition. Ultrasonic vibration at fixed frequencies was applied to TiN-coated samples for three sets of exposure times. The findings revealed that all TiN-coated samples exposed to ultrasonic vibration had improved corrosion resistance compared to untreated samples. Field emission scanning electron microscopy (FESEM) was employed to analyse sample's microstructures. The top parameter (16 kHz and 11 min) yielded the most compact coating. Ultrasonic vibration's hammering effect decreased the size of microchannels in the lining and reduced the rate of corrosion attack. The nanoindentation test showed that coated ultrasonic treated samples had a higher hardness/elasticity (H/E) ratio than untreated samples.

Properties of Ceramic Coating on Heating Surface of Waste Incineration Boiler Prepared by Slurry Method.

In order to alleviate the problem of high-temperature fly ash corrosion and slag on the heating surface of a high-parameter waste incinerator, a ceramic coating material that can be prepared in situ on the heating surface by the slurry method was studied. The ceramic coating can be formed by sintering at a lower temperature of 750 °C. Its surface and profile are very dense, and the porosity is less than 1%. The mechanical properties test results show that the ceramic coating can withstand 60 cycles of water-cooled thermal shock at 700 °C, and the bonding strength is 25.14 ± 2.21 MPa. It will not fall off in a large area when subjected to pressure load, and it has a certain degree of processable plasticity. High-temperature wettability experiments show that the ceramic coating has lower liquid-bridge force, smaller adhesion area, and shorter fouling cycle for molten corrosive fouling, and potential self-cleaning properties. Its practical mechanical properties make the coating valuable for production applications and meet expectations, and excellent antifouling properties to reduce average fouling thermal resistance and corrosion.

Microstructure and Properties of Atmospheric Plasma Sprayed (Al,Cr)2O3-TiO2 Coatings from Blends.

Coatings prepared from chromia-rich (Al,Cr)2O3 solid solution (ss) feedstock powders are intended to improve the properties of Cr2O3 coatings, but are rarely studied so far. In this work, the processability of a commercial (Al,Cr)2O3 solid solution (ss) powder containing 78 wt.% Cr2O3 by atmospheric plasma spraying (APS), the corresponding coating microstructures and properties were investigated. Possible further improvements were expected by blending with 2, 23 and 54 wt.% TiOx powder. For comparison, plain Cr2O3 and TiOx coatings were studied as well. The microstructures were analyzed using SEM, EDS and XRD measurements. Hardness (HV0.3) was measured, as well as the dry unidirectional sliding wear resistance and the abrasion wear resistance (ASTM G65). Moreover, the corrosion and electrical insulating properties were measured. The (Al,Cr)2O3 ss showed only a small change of the composition, and the formation of γ-Al2O3, as found for alumina-rich (Al,Cr)2O3 ss powders, was avoided. Compared to the plain chromia coating, some improvements of the processability and coating properties for the ss (Al,Cr)2O3 coating were found. The most balanced coating performance was achieved by blending the ss (Al,Cr)2O3 with 2 wt.% TiOx, as this coating showed both a high sliding and abrasion wear resistance, in combination with a high corrosion resistance.

Crack Evolution and Oxidation Failure Mechanism of a SiC-Ceramic Coating Reactively Sintered on Carbon/Carbon Composites.

A SiC ceramic coating was prepared on carbon/carbon composites by pack cementation. The phase composition and microstructure of the coated specimens were characterized using X-ray diffraction instrument and scanning electron microscope. The results showed that the mass-loss percentage of the coated specimen was 9.5% after being oxidized for 20 h. The oxidation failure of the SiC ceramic coating at 1773 K was analysed by non-destructive X-ray computed tomography. The effective self-healing of cracks with widths below 12.7 µm introduced during the coating preparation process and generated while the specimens cooled down from the high oxidation temperature prevented the oxidation of carbon/carbon composites. X-ray computed tomography was used to obtain three-dimensional images revealing internal damage caused by spallation and open holes on the coating. Stress induced by heating and cooling caused the formation, growth and coalescence of cracks, which in turn led to exfoliation of the coating and subsequent failure of oxidation protection.

Characteristics of Plasma Flow for Microwave Plasma Assisted Aerosol Deposition.

To validate the possibility of the developed microwave plasma source with a novel structure for plasma aerosol deposition, the characteristics of the plasma flow velocity generated from the microwave plasma source were investigated by a Mach probe with pressure variation. Simulation with the turbulent model was introduced to deduce calibration factor of the Mach probe and to compare experimental measurements for analyses of collisional plasma conditions. The results show calibration factor does not seem to be a constant parameter and highly dependent on the collision parameter. The measured plasma flow velocity, which witnessed fluctuations produced by a shock flow, was between 400 and 700 m/s. The optimized conditions for microwave plasma assisted aerosol deposition were derived by the results obtained from analyses of the parameters of microwave plasma jet. Under the optimized conditions, Y2O3 coatings deposited on an aluminum substrate were investigated using scanning electron microscope. The results presented in this study show the microwave plasma assisted aerosol deposition with the developed microwave plasma source is highly feasible for thick films with >50 µm.

Tribological and corrosion performance of the plasma-sprayed conformal ceramic coating on selective laser melted CoCrMo alloy.

Ceramic implants have superior performance due to the excellent wear resistance and biocompatibility. However, the poor machinability limits their applications. Plasma sprayed ceramic coating on the additively manufactured metal substrate not only provides a 3-dimensional conformal implant coating and but also forms a highly wear-resistant surface layer. In this paper, three types of ceramic coatings of Al2O3, ZrO2, and Al2O3-ZrO2 composite have been fabricated by atmosphere plasma spray on the CoCrMo alloy substrate prepared by selective laser melting (SLM). It has been found that the Al2O3-ZrO2 composite coating has better corrosion and wear resistance compared with the ceramic coating (Al2O3, ZrO2) and the CoCrMo substrate. The adhesion strength between the Al2O3-ZrO2 composite coating and the substrate reaches 238 MPa. In addition, the wear and corrosion resistance increase with wear progression for all the fabricated ceramic coatings. The highly dense microstructure, fewer microcracks, and the amorphous phases are deterministic factors responsible for the superior tribological and corrosion performance of the Al2O3-ZrO2 composite coating. The fabrication route has been proved very promising to manufacture high-performance implants with ceramic coating.

Ceramic Coating in Cemented Primary Total Knee Arthroplasty is Not Associated With Decreased Risk of Revision due to Early Prosthetic Joint Infection.

BACKGROUND: Prosthetic joint infection (PJI) is one of the most frequent and devastating causes of short-term revision total knee arthroplasty (TKA). In vitro evidence suggests ceramic surfaces demonstrate resistance to biofilm, but the clinical effect of bearing surface modifications on the risk of PJI remains unclear. This premier registry-based study examines the influence of ceramic bearing surface coatings on the outcome in cemented primary TKA. METHODS: In total, 117,660 cemented primary TKAs in patients with primary osteoarthritis recorded in the German arthroplasty registry since 2012 were followed up for a maximum of 3 years. The primary endpoint was risk of revision for PJI on ceramic coated and uncoated cobalt-chromium-molybdenum femoral components. Propensity score matching for age, gender, obesity, diabetes mellitus, depression and Elixhauser comorbidity index, and substratification on common design twins with and without coating was performed. RESULTS: In total, 4637 TKAs (85.1% female) with a ceramic-coated femoral component were identified, 42 had been revised for PJI and 122 for other reasons at 3 years. No survival advantage due to the risk of revision for PJI could be determined for ceramic-coated components. Revision for all other reasons demonstrated a significant higher rate for TKAs with ceramic-coated components. However, the results of this were confounded by a strong prevalence (20.7% vs 0.3%) of metal sensitivity in the ceramic-coated group. CONCLUSION: No evidence of reduced risk for PJI due to ceramic-coated implants in cemented primary TKA was found. Further analysis for revision reasons other than PJI is required.

Changes in the Coating Composition Due to APS Process Conditions for Al2O3-Cr2O3-TiO2 Ternary Powder Blends.

Thermally sprayed coatings from the single oxides and binary compositions of the Al2O3-Cr2O3-TiO2 system show multifunctional properties. Ternary compositions are promising for further improvement in their performance. The stability of the composition during coating formation is an important issue for blended feedstock powders in order to obtain the desired properties. This work focuses on the compositional changes of a ternary blend of Al2O3, Cr2O3 and TiOx powders of equal content by mass in a conventional atmospheric plasma spraying (APS) process using an Ar/H2 plasma gas mixture. By increasing the argon flow rate at constant hydrogen flow rate, the total plasma gas flow rate and the Ar/H2 ratio were varied. For the highest argon flow rate, this resulted in an average particle velocity of 140% and an average particle temperature of 90% of the initial values, respectively. Coating composition and microstructure were studied by optical microscopy, SEM, including EDS analyses, and XRD. In addition, the coating hardness and electrical impedance were also measured. Differences in the "difficulty of melting factor" (DMF) and the thermal diffusivity of the three oxides appear to be responsible for the dramatic change of the coating composition with an increasing argon flow rate. For the highest argon flow rate applied, besides TiO2, the coating contains only 8 wt.% Al2O3, while the Cr2O3 content remained almost constant. At the same time, the change of the Ar/H2 ratio resulted in the formation of stoichiometric TiO2 in the coating by oxidation of TiOx in the feedstock powder. Moreover, a small content of titanium was found in the Cr2O3 splats, showing that there are only limited interactions between the large oxide powder particles. Thus, the study has shown that stability of the chemical composition during spraying of ternary powder blends is strongly influenced by the process conditions.

Numerical Simulation and Experimental Investigation of Laser Ablation of Al2O3 Ceramic Coating.

This paper presents an evaluation of the molten pool laser damage done to an Al2O3 ceramic coating. Mechanism analysis of the laser damage allowed for a 2D finite element model of laser ablation of the Al2O3 ceramic coating to be built. It consisted of heat transfer, laminar flow, and a solid mechanics module with the level set method. Results showed that the laser damage mechanisms through laser ablation were melting, gasification, spattering, and micro-cracking. The ablation depth and diameter increased with the increasing laser ablation time under continuous irradiation. The simulation profile was consistent with the experimental one. Additionally, the stress produced by the laser ablation was 3500-9000 MPa, which exceeded the tensile stress (350-500 MPa), and fracturing and micro-cracks occurred. Laser damage analysis was performed via COMSOL Multiphysics to predict laser damage morphology, and validate the 3D surface profiler and scanning electron microscope results.

Ultrasound-Assisted Hydroxyapatite-Decorated Breath-Figure Polymer-Derived Ceramic Coatings for Ti6Al4V Substrates.

The introduction of nanoparticles (NPs) into the breath-figure-templated self-assembly (BFTSA) process is an increasingly common method to selectively decorate a surface porous structure. In the field of prosthetic devices, besides controlling the morphology and roughness of the structure, NPs can enhance the osteointegration mechanism because of their specific ion release. Among the most widely used NPs, there are silica and hydroxyapatite (HAp). In this work, we propose a novel one-stage method to fabricate NP-decorated surface porous structures that are suitable for prosthetic coating applications. This technique combines the classical direct BFTSA process with the cavitation effect induced by an ultrasonic atomizer that generates a mist of water droplets with embedded NPs. Coatings were successfully obtained by combining a UV cross-linkable polymer precursor, alkoxy silicone, with synthesized HAp NPs, on Ti6Al4V alloy discs. The cross-linked polymeric surface porous structures at selected concentrations were then pyrolyzed in an ammonia atmosphere to obtain a silicon oxynitride (SiON) ceramic coating. Herein, we report the chemical and morphological analyses of both the polymeric and ceramic coatings as well as the effect of NPs at the interface.

An In Vivo Study in Rat Femurs of Bioactive Silicate Coatings on Titanium Dental Implants.

Silica-based ceramics have been proposed for coating purposes to enhance dental and orthopedic titanium (Ti) implant bioactivity. The aim of this study was to investigate the influence of sphene-based bioceramic (CaO.TiO2.SiO2) coatings on implant osseointegration in vivo. Sphene coatings were obtained from preceramic polymers and nano-sized active precursors and deposited by an automatic airbrush. Twenty customized Ti implants, ten sphene-coated and ten uncoated rough implants were implanted into the proximal femurs of ten Sprague-Dawley rats. Overall, cortical and cancellous bone-to-implant contact (BIC) were determined using micro-computed tomography (micro-CT) at 14 and 28 days. Moreover, peri-implant bone healing was histologically and histomorphometrically evaluated. The white blood cell count in the synovial fluid of the knee joints, if present, was also assessed. No difference in the BIC values was observed between the sphene-coated and uncoated implants, overall and in the two bone compartments (p > 0.05). Delamination of the coating occurred in three cases. Consistently with micro-CT data, the histological evaluation revealed no differences between the two groups. In addition, no synovial fluid could be collected on the test side, thus confirming sphene biocompatibility. In conclusion, sphene coating was found to be a suitable material for biomedical applications. Further studies are needed to improve coating adhesion to the implants.

Three-Dimensional Printed Porous Titanium Screw with Bioactive Surface Modification for Bone-Tendon Healing: A Rabbit Animal Model.

The interference screw fixation method is used to secure a graft in the tibial tunnel during anterior cruciate ligament reconstruction surgery. However, several complications have been reported, such as biodegradable screw breakage, inflammatory or foreign body reaction, tunnel enlargement, and delayed graft healing. Using additive manufacturing (AM) technology, we developed a titanium alloy (Ti6Al4V) interference screw with chemically calcium phosphate surface modification technology to improve bone integration in the tibial tunnel. After chemical and heat treatment, the titanium screw formed a dense apatite layer on the metal surface in simulated body fluid. Twenty-seven New Zealand white rabbits were randomly divided into control and additive manufactured (AMD) screw groups. The long digital extensor tendon was detached and translated into a tibial plateau tunnel (diameter: 2.0 mm) and transfixed with an interference screw while the paw was in dorsiflexion. Biomechanical analyses, histological analyses, and an imaging study were performed at 1, 3, and 6 months. The biomechanical test showed that the ultimate pull-out load failure was significantly higher in the AMD screw group in all tested periods. Micro-computed tomography analyses revealed early woven bone formation in the AMD screw group at 1 and 3 months. In conclusion, AMD screws with bioactive surface modification improved bone ingrowth and enhanced biomechanical performance in a rabbit model.

Microstructure and Wear Properties of Micro Arc Oxidation Ceramic Coatings.

The interaction effect of micro arc oxidation (MAO) parameters on the microstructure and wear properties was investigated. The results showed that the electric current and oxidation time significantly influenced the thickness and grinding crack width of the ceramic coatings within the range of the selected parameters, and the interaction effect of the electrical parameters was not obvious. The surface morphology, cross-section morphology, and element distribution of the coatings were observed using scanning electron microscopy (SEM) with energy dispersive spectroscopy (EDS) and X-ray diffraction (XRD). The results showed that ceramic coatings with γ-Al2O3 and α-Al2O3 formed, which enhanced the coating performance. After that, the microhardness and wear resistance were tested. Under the optimal process, the microhardness of a coating section was up to 1200 HV0.1, and the friction coefficient was just 0.3. When wear occurred, the volcanic microstructures experienced extrusion and deformation, and then peeled off under shear stress, which led to the formation of a grinding crack. The main failure modes of the micro arc oxidation coatings were abrasive wear and spalling failure.