A review on the fatigue performance of micro-arc oxidation coated Al alloys with micro-defects and residual stress

Unavoidable issues of micro-arc oxidation (MAO) coated Al alloys are the micro-defects and residual stress generation. Some scientists have reported the effects of micro-defects and residual stress on the fatigue performance of MAO coated samples. However, the influence of the residual stress sign in the MAO coating and substrate beneath the interface on the fatigue damage behavior of the substrate was controversial. Moreover, the coupling mechanism between micro-defects and residual stress on the fatigue performance of the MAO coated samples was nebulous. These present a challenge for the collaborative design of micro-defects and residual stress to optimize fatigue performance. Aiming at the issues, this paper summarized the influencing factors of MAO coatings on the fatigue performance of the substrate. From two aspects of microstructure characterization and stress analysis, the coupling mechanism between micro-defects and residual stress in fatigue failure was elucidated. And the mechanism of the micro-defects and residual stress on the fatigue damage behavior was developed. Finally, strategies to optimize the fatigue performance of MAO coated Al alloys were proposed. The results of this study have great guiding significance in regulating micropores, cracks, interface defects, and residual stress in MAO coatings in order to extend fatigue life.