The formation of alumina-based coatings on aluminium by AC plasma electrolytic oxidation (PEO) has been investigated using a silicate electrolyte with selective additions of fine zirconia particles. The coatings comprised an amorphous barrier layer, a relatively dense intermediate layer and a more porous outer layer that contained silicon species. Zirconia was incorporated non-uniformly into the outer layer and, to a limited extent, the intermediate layer, as both particles and a component of cellular microstructures. Following treatments firstly in zirconia-containing electrolyte and secondly in zirconia-free electrolyte, the zirconia did not extend beyond about the middle of the intermediate layer, indicating its limited inward mass transfer during microdischarges. The coating efficiency decreased at oxidation times in excess of 40 min due to dissolution of either the substrate or the coating, or physical loss of coating material. The oxidation of aluminium consumed on average similar to 29% of the anodic charge; the remainder was used mainly in generation of oxygen gas. (C) 2009 Elsevier Ltd. All rights reserved.