Abstract:The combined effects of voltage, pulse frequency, duty cycle and processing time on the corrosion resistance of micro-arc oxidation coatings on TC4 titanium alloy were investigated using range analysis, with a subsequent objective of exploring the significance relationship of electrical parameters and their optimal combination. The influence mechanism of electrical parameters on the corrosion resistance of the coatings was explored by combining coating morphology and phase composition. A regression equation was established to facilitate regulation of the corrosion resistance of micro-arc oxidation coatings through manipulation of electrical parameters. The results show that the duty cycle exhibits the most significant influence on the electrochemical corrosion resistance of the coating, followed by pulse frequency and voltage, while the processing time shows a comparatively lesser effect. The duty cycle and pulse frequency influence both structure and performance characteristics of the coating by modulating arc ignition discharge duration and arc quenching cooling time. Increasing voltage, duty cycle and processing time, or decreasing pulse frequency can elevate the power supply output, which leads to an increase in coating thickness and pore size in microporous structures while reducing coating densification. Furthermore, this process promotes more efficient generation of Al2TiO5 in the coating; however, it ultimately results in diminished electrochemical corrosion resistance. The results of correlation coefficient testing indicate a strong relationship between the dependent and independent variables within the established regression equation. This finding provides theoretical support and predicting methods to regulate performance characteristics of titanium alloy micro-arc oxidation coatings.