Plasma Electrolytic Oxidation
A low-temperature, eco-friendly ceramic process that works on complex parts and light alloys — with industrial-grade hardness and adhesion.
Advanced PEO converts the surface of aluminium, magnesium and titanium into a dense, hard ceramic oxide using an eco-friendly alkaline chemistry at just 20–30°C.
What is Plasma Electrolytic Oxidation?
Plasma Electrolytic Oxidation (PEO) is an advanced electrochemical surface treatment that transforms the surface of light metals — aluminium, magnesium and titanium — into a dense, hard ceramic oxide layer. Unlike conventional anodising, PEO uses micro-plasma discharges in an eco-friendly alkaline electrolyte to grow the coating directly from the substrate, delivering industrial-grade hardness and adhesion at low process temperatures.
How the Ceramic Coating Forms
The component is immersed in an alkaline electrolyte and subjected to high-voltage pulses. Localised plasma discharges convert the native metal surface into a crystalline ceramic oxide with hardness of 900–2000 HV and adhesion of 200–350 MPa — far beyond hard anodising. Because the layer grows from the substrate itself, it bonds metallurgically and coats complex geometries without the line-of-sight limits of plasma spray.
From a Corroding Part to a Protected Asset
An uncoated aluminium seawater pump impeller can suffer pitting corrosion within months — causing unplanned shutdowns and frequent part replacement. After PEO treatment, the same impeller carries a corrosion- and cavitation-resistant ceramic surface, extends its service interval several times over, and leaves no toxic chemical residue. Protecting the surface once replaces a recurring cycle of maintenance and downtime.
An Eco-Friendly, Low-Temperature Process
PlasmaOx uses an eco-friendly alkaline chemistry at just 20–30°C — with no aggressive acids, chromates or hazardous heavy metals, and no complex pretreatment. The process is industry-proven, achieves a high coating rate, and directly replaces chrome and thermal-spray chemistries that are being phased out by regulation.
A Surface-Engineering Platform — Not a Single Coating
PlasmaOx is built as three connected platforms. Platform A — Core PEO delivers corrosion, wear and thermal protection for aluminium, magnesium and titanium. Platform B — Hybrid PEO combines PEO with sol-gel and polymer top-coats for tuned hardness, sealing and colour. Platform C — Smart Surfaces engineers functional surfaces for additively manufactured parts and next-generation light alloys such as A20X and AZ91. Our proprietary electrolyte formulations and alloy-specific process recipes — not the equipment — are what make the platform defensible.
How PlasmaOx Compares
See how our advanced PEO technology outperforms conventional coating methods.
| Property | Plasma Spray | Hard Anodising | Traditional PEO | PlasmaOx Advanced PEO★ Best |
|---|---|---|---|---|
| Process Temperature | 1000–1500°C | ~0°C | 15–20°C | 20–30°C |
| Hardness (HV) | 700–1500 | 200–600 | 900–2000 | 900–2000 |
| Adhesion to Substrate | 5–80 MPa | 16–20 MPa | 100–300 MPa | 200–350 MPa |
| Complex Geometries | No (line-of-sight) | Edge cracking | Yes | Yes |
| Dielectric Strength | 6–16 kV/mm | 10–30 kV/mm | 20–30 kV/mm | 40–50 kV/mm |
| Process Chemistry | Gas | Aggressive acids | Alkaline | Eco-friendly alkaline |