A process for the corrosion protection of metals such as magnesium, aluminium or titanium, where at least two steps are used, including both plasma electrolytic oxidation and chemical passivation. The combination of these two processing steps enhances the corrosion resistance performance of the surface beyond the capability of either of the steps in isolation, providing a more robust protection system. This process may be used as a corrosion protective coating in its own right, or as a protection-enhancing pre-treatment for top-coats such as powder coat or e-coat. When used without an additional top-coat, the treated parts can still retain electrical continuity with and adjoining metal parts. Advantages include reduced cost and higher productivity than traditional plasma-electrolytic oxidation systems, improved corrosion protection, greater coating robustness and electrical continuity.

An aluminum member includes: a substrate formed of aluminum or an aluminum alloy that contains 0 to 10% by mass of magnesium, 0.1% by mass or less of iron, and 0.1% by mass or less of silicon and a balance of which is aluminum and unavoidable impurities; and an anodic oxide coating formed on a surface of the substrate. A surface of the substrate on the anodic oxide coating side has an arithmetical mean height Sa of 0.1 to 0.5 μm, a maximum height Sz of 0.2 to 5 μm, and an mean width of roughness profile elements Rsm of 0.5 to 10 μm, where the arithmetical mean height Sa, the maximum height Sz, and the mean width of roughness profile elements Rsm are measured after the anodic oxide coating is removed.

An aluminum member includes: a substrate formed of aluminum or an aluminum alloy that contains 0 to 10% by mass of magnesium, 0.1% by mass or less of iron, and 0.1% by mass or less of silicon and a balance of which is aluminum and unavoidable impurities; and an anodic oxide coating formed on a surface of the substrate. A surface of the substrate on the anodic oxide coating side has an arithmetical mean height Sa of 0.1 to 0.5 μm, a maximum height Sz of 0.2 to 5 μm, and an mean width of roughness profile elements Rsm of 0.5 to 10 μm, where the arithmetical mean height Sa, the maximum height Sz, and the mean width of roughness profile elements Rsm are measured after the anodic oxide coating is removed.

In a process for anodizing a metal object (12), the metal object (12) is contacted with an anodizing electrolyte (32), and is first pre-anodized so as to grow a thin oxide film on the surface. The microscopic surface area is then deduced from electrical measurements either during pre-anodizing or on the pre-anodized surface. The metal object (12) can then be anodized. This is applicable when treating an implant to provide a surface that has the ability to incorporate biocidal material such as silver ions. The pre-anodizing uses a low voltage, for example no more than 2. V, and may take less than 120 seconds.

In a process for anodizing a metal object (12), the metal object (12) is contacted with an anodizing electrolyte (32), and is first pre-anodized so as to grow a thin oxide film on the surface. The microscopic surface area is then deduced from electrical measurements either during pre-anodizing or on the pre-anodized surface. The metal object (12) can then be anodized. This is applicable when treating an implant to provide a surface that has the ability to incorporate biocidal material such as silver ions. The pre-anodizing uses a low voltage, for example no more than 2. V, and may take less than 120 seconds.

A method of forming a micro-structure involves forming a multi-layered structure including i) an oxidizable material layer on a substrate and ii) another oxidizable material layer on the oxidizable material layer. The oxidizable material layer is formed of an oxidizable material having an expansion coefficient, during oxidation, that is more than 1. The method further involves forming a template, including a plurality of pores, from the other oxidizable material layer, and growing a nano-pillar inside each pore. The nano-pillar has a predefined length that terminates at an end. A portion of the template is selectively removed to form a substantially even plane that is oriented in a position opposed to the substrate. A material is deposited on at least a portion of the plane to form a film layer thereon, and the remaining portion of the template is selectively removed to expose the nano-pillars.

A method of preparing aluminum alloy-resin composite and an aluminum alloy-resin composite obtained by the same are provided. of the method comprises: S1: anodizing a surface of an aluminum alloy substrate to form an oxide layer on the surface, the oxide layer including nanopores; S2: immersing the resulting aluminum alloy substrate obtained in step S1 in a buffer solution having a pH of about 10 to about 13, to form a corrosion pores on an outer surface of the oxide layer; and S3: injection molding a resin onto the surface of the resulting aluminum alloy substrate obtained in step S2 in a mold to obtain the aluminum alloy-resin composite.

A method of preparing aluminum alloy-resin composite and an aluminum alloy-resin composite obtained by the same are provided. of the method comprises: S1: anodizing a surface of an aluminum alloy substrate to form an oxide layer on the surface, the oxide layer including nanopores; S2: immersing the resulting aluminum alloy substrate obtained in step S1 in a buffer solution having a pH of about 10 to about 13, to form a corrosion pores on an outer surface of the oxide layer; and S3: injection molding a resin onto the surface of the resulting aluminum alloy substrate obtained in step S2 in a mold to obtain the aluminum alloy-resin composite.

A substrate support and method of forming a substrate support are described herein. In one example, a substrate support includes an aluminum body having an upper surface configured to support a large area substrate, a heater element, and a filler material. The aluminum body has a groove formed therein. The heater element is disposed in the groove. The filler material is in contact with the heater element and fills the groove. The contact between the filler material and the perimeter of the heater element is the only material interface within the groove, and the filler material has a larger grain size than a grain size of the aluminum body.

A substrate support and method of forming a substrate support are described herein. In one example, a substrate support includes an aluminum body having an upper surface configured to support a large area substrate, a heater element, and a filler material. The aluminum body has a groove formed therein. The heater element is disposed in the groove. The filler material is in contact with the heater element and fills the groove. The contact between the filler material and the perimeter of the heater element is the only material interface within the groove, and the filler material has a larger grain size than a grain size of the aluminum body.