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Hard anodic coatings were formed on 6061-T6 aluminium alloy samples using direct current. Surface morphology and cross-section of coatings, as well as their hardness and corrosion behaviour, were studied. It was found that decreasing the applied current density from 55 to 35 mA cm −2  resulted in more uniform coatings with fewer surface defects, lower porosity, and higher hardness values. The optimum electrolyte concentration and hard-anodising time, where less defective coatings were achieved, were found to be 180 g L −1  and 50 min, respectively. The hardness of the optimum film was around 500 HV, and its corrosion current density was 3.2 × 10 −9 A cm −2 . All other samples that were produced at different current densities (30-55 mA cm −2 ), times (40-100 min), and electrolyte concentrations (25-220 g L −1 ) had lower hardness and corrosion resistance than the optimum coating. The polarisation resistance of the optimum coating was about 1100 times higher than the bare substrate.

Characteristics and corrosion resistance of hard-anodised 6061-T6 aluminium alloy