Abstract
The adherence of plasma sprayed NiCrAlY bond coats can be improved by an appropriate substrate surface finish. The interface fracture energy for crack propagation along the coating/substrate interface has been measured for different surface roughness by means of a specially designed four-point bending test. An increase of the interface fracture energy of about 15% was observed for a three times higher surface roughness. In addition, four-point bending tests with the coating on the side face of bending specimens were performed to analyze the fracture and spalling behavior of the coatings both under large tensile and compressive substrate deformations.
This is a preview of subscription content, log in via an institution to check access.
Similar content being viewed by others
References
C.Y. Jian, T. Hashida, H. Takahashi, and M. Saito: “Thermal Shock and Fatigue Resistance Evaluation of Functionally Graded Coating for Gas Turbine Blades by Laser Heating Method,” Comps. Eng., 1995, 5(7), pp. 879–89.
H. Balke, I. Hofinger, C. Häusler, H.-A. Bahr, H.-J. Weiß, and G. Kirchhoff: “Fracture Mechanical Damage Modelling of Thermal Barrier Coatings,” Arch. Appl. Mech., 2000, 70, pp. 193–200.
I. Hofinger, M. Oechsner, H.-A. Bahr, and M.V. Swain: “Modified Four-Point Bending Specimen for Determining the Interface Fracture Energy for Thin, Brittle Layers,” Int. J. Fract., 1998, 92, pp. 213–20.
I. Hofinger, H.-A. Bahr, H. Balke, G. Kirchhoff, C. Häusler, and H.-J. Weiß: “Fracture Mechanical Modelling and Damage Characterization of Functionally Graded Thermal Barrier Coatings by Means of Laser Irradiation,” Mater. Sci. Forum, 1999, 308–311, pp. 450–56.
M. Hollatz, M. Bobeth, and W. Pompe: “Failure of Alumina Scales on NiAl Under Graded Scale Loading,” Mater. Corros., 1996, 47, pp. 633–45.
R.C. Brink: “Material Property Evaluation of Thick Thermal Barrier Coating Systems,” J. Eng. Gas Turbines Power, 1989, 111(7), pp. 570–77.
C.C. Berndt: “Thermally Sprayed Coatings: Properties and Applications” in Surface Modification Technologies IV, T.S. Sudarshan, D.G. Bhat, and M. Jeandin, ed., The Materials and Metals Society, Warrendale, PA, 1991, pp. 193–213.
K.F. Wesling, D.F. Socie, and M.B. Beardsley: “Fatigue of Thick Thermal Barrier Coatings,” J. Am. Ceram. Soc., 1994, 77(7), pp. 1863–68.
M.S. Hu and A.G. Evans: “The Cracking and Decohesion of Thin Films on Ductile Substrates,” Acta Metall., 1989, 37(3), pp. 917–25.
P.G. Charalambides, J. Lund, A.G. Evans, and R.M. McMeeking: “A Test Specimen for Determining the Fracture Resistance of Bimaterial Interfaces,” J. Appl. Mech., 1989, 56, pp. 77–82.
A. Cazzato and K.T. Faber: “Fracture Energy of Glass-Alumina Interfaces Via the Bimaterial Bend Test,” J. Am. Cer. Soc., 1997, 80(1), pp. 181–88.
J.W. Hutchinson and Z. Sou: “Mixed Mode Cracking in Layered Materials,” Adv. Appl. Mech., 1992, 29, p. 63.
A.G. Evans, M. Rühle, B.J. Dalgleish, and P.G. Charalambides: “The Fracture Energy of Bimaterial Interfaces,” Mater. Sci. Eng., 1990, A126, pp. 53–64.
Author information
Authors and Affiliations
Rights and permissions
About this article
Cite this article
Hofinger, I., Möller, J., Bobeth, M. et al. Effect of substrate surface roughness on the adherence of NiCrAlY thermal spray coatings. J Therm Spray Tech 11, 387–392 (2002). https://doi.org/10.1361/105996302770348781
Received:
Revised:
Issue Date:
DOI: https://doi.org/10.1361/105996302770348781