The Study on the Overall Plasma Electrolytic Oxidation for 6061–7075 Dissimilar Aluminum Alloy Welded Parts Based on the Dielectric Breakdown Theory

Electrical connection of dissimilar metals will lead to galvanic corrosion. Therefore, overall surface treatment is necessary for the protection of dissimilar metal welded parts. However, serious unbalanced reactions may occur during overall surface treatment, which makes it difficult to prepare integral coating. In this paper, an overall ceramic coating was fabricated by plasma electrolytic oxidation to wrap the 6061–7075 welded part integrally. Moreover, the growth mechanism of the coating on different areas of the welded part was studied based on the dielectric breakdown theory. The reaction sequence of each area during the treatment was verified through specially designed dielectric breakdown tests. The results showed that the high impedance overall of ceramic coating can inhibit the galvanic corrosion of the 6061–7075 welded part effectively.