Based on orthogonal experiments, the effects of voltage, frequency, duty ratio and their interactions on the thickness and corrosion resistance of coatings prepared by plasma electrolytic oxidation (PEO) on aluminum in an alkaline silicate-containing electrolyte were investigated. The thicknesses of these coatings were obtained by measuring their cross-section using Image J software. Their corrosion resistances were evaluated in HCl and NaCl media through spot test and electrochemical test. The results show that the experimental design of this study is the key to investigate the interactions among these electrical parameters. Additionally, not only each independent factor, but also their interactions exhibit a remarkable influence on the coatings. The combination of high voltage, low frequency and large duty ratio significantly increases the coating thickness and content of the corrosion resistance phase, and thus improves the corrosion resistance of the coating in HNO3 medium. Conversely, the coating possessing the densest microstructure and best corrosion resistance in NaCl medium is obtained when low voltage and high frequency match with a small duty ratio. © 2020 The Nonferrous Metals Society of China