Effect of surface roughness on deposition of PS-PVD thermal barrier coating ceramic coating
ZENG Wei1,2, MAO Jie1,2, MA Jing-tao1,2,3, DENG Chang-guang1,2, DENG Zi-qian1,2, DENG Chun-ming1,2, SONG Peng3
1. National Engineering Laboratory for Modern Materials Surface Engineering Technology, Guangdong Institute of New Materials, Guangzhou 510651, China;
2. The Key Lab of Guangdong for Modern Surface Engineering Technology, Guangdong Institute of New Moterials, Guangzhou 510651, China;
3. Faculty of Material Science and Engineering, Kunming University of Science and Technology, Kunming 650093, China
Abstract：The effect of surface roughness based on PS-PVD process on the structure of YSZ ceramic coating was studied. The influence mechanism of surface roughness on gas-phase deposition and structure formation of ceramic coating was discussed. YSZ ceramic coating was prepared by PS-PVD process on K417G superalloy prefabricated with NiCoCrAlYTa bond coating. The morphology and structural characteristics of PS-PVD YSZ coating were analyzed by means of SEM, roughness detector and 3D surface topography instrument. Substrate surface roughness has a great influence on PS-PVD coating structure. When the surface roughness of the substrate is Ra ≤ 2μm, 2μm < Ra < 6μm, and Ra ≥ 6μm, respectively, the coating roughness is in the range of 3.5-5, 6-10μm and 10-15μm, respectively. The diameter of cauliflower head increases with the increase of the surface roughness of substrate. The dP=38.5μm, d280S=25.5μm, d60S=38.7μm, d24S=102μm and dS=137μm. In the process of PS-PVD gas-phase deposition, surface roughness mainly affects the growth and formation of coating differential structures through shadow effect. With the increase of substrate surface roughness, YSZ ceramic coating is affected by shadow effect and the size of cauliflower head and the gap width between columnar structures are increased, forming a relatively loose structure.
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