Plasma electrolytic oxidation for integrated luminescent ceramics: when the coating itself becomes the device.

Abstract

A persistent limitation in advanced functional materials is the trade-off between optical performance and mechanical durability in extreme environments. Plasma electrolytic oxidation (PEO) offers a route by growing metallurgically bonded luminescent ceramics directly on engineering metals. This review establishes an integrated framework for these systems. We first benchmark PEO against conventional coating technologies. We then analyze composition-structure-property relationships across scales. By combining density functional theory with spatial-spectral techniques such as atom probe tomography and cathodoluminescence, we clarify how transient plasma micro-discharges at the solid-liquid interface influence defect formation, local luminescence coordination, and phase evolution. The "coating-as-device" concept converts coatings from passive protective layers into functional cores, with applications in structural health monitoring, hardware security, and extreme-environment sensing. Finally, we outline a roadmap based on machine-learning-guided matrix design, stimuli-responsive surfaces, and closed-loop sustainable manufacturing.

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