Microwave processing is an energy-efficient advanced technique to prepare materials with finer microstructure and better mechanical properties. In the present paper, microwave energy was utilized for the development of oxide coatings on blocks of commercial aluminium of various geometrical shapes. Experimental results revealed that the geometrical term i.e. the volume to surface ration had a dominant influence on the microwave induced oxidation behaviour of the samples. In all the cases, coating thickness and its density progressively increased with increasing microwave exposure time. The coating phase was found out to be a-Al2O3 by XRD analysis. The coating microstructure and elemental analysis as examined by SEM and EDAX respectively have been discussed in detail. Adhesion of coatings was studied by using the scratch test.
