Plasma electrolytic oxidation (PEO), applied to light metals such as titanium, aluminum, and magnesium, creates a two‑layer coating and has become increasingly important in metal coatings. However, due to the high voltage and temperature of the process, no online instrument could monitor the underlying mechanism. This paper presents a new image proving that the surface of PEO‑coated Mg3ZnCa boiled during the process and argues that three hypotheses are involved in the PEO mechanism based on boiling caused by tolerating high voltage during the PEO process, which could explain the current‒voltage diagram of the process. Finally, nanoindentation was used to measure the elastic module and hardness of the PEO layers. The nanoindentation test results revealed the similarity of the elastic module of the outer porous layer and the primary alloy, with values of 40.25 GPa and 41.47 GPa, respectively, conirming that the outer porous layer corresponds to the cold plasma‑gas phase formed during the PEO process.
