Silesian University of Technology

Assessment of the potential for improving the surface properties of copper alloys with zinc and nickel additions through the plasma electrolytic oxidation process

Programme title: Support for Students in Enhancing Their Competences and Skills (Call II)
Offer number: N190
Amount of funding and total project value: PLN 48,464.12
Internal acronym: Brass-a-nova (BAN)
Project duration: 7 January – 30 September 2026

#FunduszeUE

A New Chapter for Copper and Its Alloys

Copper and its alloys, such as brass and cupronickel, are valued for their excellent thermal and electrical conductivity; however, their broad application is often limited by low hardness, poor resistance to abrasive wear, and susceptibility to corrosion in aggressive environments. To overcome these barriers and limitations, surface modification using the plasma electrolytic oxidation (PEO) process can be applied. Through the generation of plasma micro-discharges on the metal surface, porous, tightly adherent ceramic coatings are formed, composed mainly of copper oxides. As a result of this process, conventional copper alloys can gain exceptional durability, including new surface properties such as electro- or photocatalytic functionality.

Advanced Coatings Engineering as the Key to a Better Tomorrow

In order to produce high-quality PEO coatings, it will be necessary to optimize the process itself by investigating the influence of the composition of electrolytic baths (including those based on aluminates with phosphate additives) on the microstructure of the protective layer and its properties.

Future Applications: Photo‑ and Electrocatalysis

PEO technology paves the way for entirely new, unconventional applications of copper alloys. The complex oxide layers formed during the process exhibit unique semiconducting properties that can be tailored depending on the electrolyte used. The ceramic coatings produced on brass or cupronickel show significant potential for high photo‑ and electrocatalytic activity. As a result, these materials can be applied in solutions related to modern environmental remediation technologies or the processing of unwanted by‑products of human activity.

Warm‑Up Seminar

On 20 April 2026, a scientific seminar was held at the Student Creativity Center of the Silesian University of Technology as part of the “From Students for Students” initiative. Maciej Gdala and Łukasz Gardas took an active part in the event, presenting topics related to the application of plasma electrolytic oxidation (PEO) for copper and its alloys.

Both presentations attracted considerable interest from participants, which was reflected in an extensive discussion and numerous questions concerning both technological aspects and potential applications of the presented research.

The seminar served as an important substantive warm‑up ahead of the upcoming international scientific conferences in the United States (249th ECS Meeting, Seattle) and Serbia (41st ISE Topical Meeting, Belgrade), where the results of the ongoing research projects are planned to be presented.

Photos (Author: Y. Husak)

Photo gallery from the trip to the USA (photos: M. Gdala, Ł. Gardas)

Presentation of Research Results in the Emerald City

Maciej Gdala and Łukasz Gardas had the opportunity to participate in one of the largest international conferences dedicated to the broad field of electrochemistry—the 249th ECS Meeting, covering topics ranging from fuel cell research to surface modification of alloys. The conference took place in Seattle from 24 to 28 May 2026. During the event, the students attended numerous presentations on the latest advances in photo- and electrocatalysis, as well as surface modification technologies for corrosion protection. They also participated in the poster session, where M. Gdala presented a poster entitled "Pulsed bi-polar plasma electrolytic oxidation of copper-based substrates: chemical composition & surface properties", while Ł. Gardas focused on potential applications in electrocatalysis with his poster "Electrocatalytic Potential of Copper Alloys Treated by Plasma Electrolytic Oxidation".

There was also time to explore the city and experience the local culture. The students visited attractions such as the Space Needle, the Museum of Glass Art, the Pacific Science Center, the Seattle Aquarium, and the local zoo. They also had the opportunity to try authentic American burgers and the popular dish mac and cheese.

Link to the ŁG abstract: https://ecs.confex.com/ecs/249/meetingapp.cgi/Paper/215363

Link to the MG abstract: https://ecs.confex.com/ecs/249/meetingapp.cgi/Paper/215319

And a week later – off to the capital of Serbia!

Another international conference attended by the students was the 41st Topical Meeting of the International Society of Electrochemistry (ISE), also dedicated to electrochemists, but this time held in sunny Belgrade!

“We had the opportunity to attend many interesting presentations and meet numerous enthusiasts working in the fields of corrosion and photocatalysis. We also could not miss the chance to do some sightseeing—from the Nikola Tesla Museum to the magnificent Belgrade Fortress and Republic Square. As always, we made sure to explore the local cuisine, including the purchase of the very popular and highly relevant to our research ‘Plazma’ biscuits 🙂” – comments M. Gdala.

During the poster session, the students presented posters within closely related research areas, focusing on corrosion properties (M. Gdala – "Corrosion Performance of Copper-Zinc and -Nickel Alloys Treated by Plasma Electrolytic Oxidation Technology") and the use of oxide layers in photocatalysis (Ł. Gardas –"Towards Greener Synthesis of Photocatalysts: Plasma Electrolytic Oxidation of Cu-Zn-Ni Alloy Materials").

Link to the ŁG abstract: https://fullprocess.fontismedia.com/infiles/doc_production/abs260130.pdf

Link to the MG abstract: https://fullprocess.fontismedia.com/infiles/doc_production/abs260122.pdf