Radek Musalek, Tomas Tesar, Jakub Minarik, Jiri Matejicek, Frantisek Lukac, Ole Peters, Sebastian Kraft, Udo Loeschner, Joerg Schille, Jonas Dudik, Jiri Martan
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All surface patterns were thoroughly periodical and their surface roughness ranged from <i>S</i><sub><i>a </i></sub>= 4.5 to 10.3 µm, significantly surpassing conventional grit-blasting. Pulsed and continuous wave lasers showed very high process rates (up to 54.5 mm<sup>2</sup>/s and 323.6 mm<sup>2</sup>/s, respectively) and tendency to develop network of shallow surface cracks. Ultrashort pulsed laser technology was slower (process rate 1.65 mm<sup>2</sup>/s) but the surface was crack-free with desirable miniature anchoring points. Plasma spraying was carried out with powder, solution, and suspension feedstocks providing an experimental matrix demonstrating potential benefits and risks of each pattern-feedstock combination. Not all combinations led to successful coating deposition, but results show that microstructure of the coating may be deliberately controlled by laser texturing, in particular periodic substrate pattern led to periodic coating microstructure in the case of suspension spraying. Also adhesion/cohesion of the coating to the substrate may be in many cases significantly improved by laser patterning of the substrate. The highest coating adhesion/cohesion strength (26.2 ± 4.8 MPa) was achieved for the coating deposited from solution on pillar patterns. 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Yttria-stabilized zirconia (YSZ) was selected as model ceramic for both substrates and coating. Three different types of patterns were produced by three different laser technologies: dimples with nominal depth of 15 and 30 µm (pulsed nanosecond laser), grids with nominal depth of 15 and 30 µm (continuous wave laser), and pillars with nominal depth 30 µm (ultrashort pulsed femtosecond laser). All surface patterns were thoroughly periodical and their surface roughness ranged from <i>S</i><sub><i>a </i></sub>= 4.5 to 10.3 µm, significantly surpassing conventional grit-blasting. Pulsed and continuous wave lasers showed very high process rates (up to 54.5 mm<sup>2</sup>/s and 323.6 mm<sup>2</sup>/s, respectively) and tendency to develop network of shallow surface cracks. Ultrashort pulsed laser technology was slower (process rate 1.65 mm<sup>2</sup>/s) but the surface was crack-free with desirable miniature anchoring points. 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High-Speed Laser Patterning of YSZ Ceramic Substrates for Plasma Spraying: Microstructure Manipulation and Adhesion of YSZ Coatings
This paper introduces novel possibilities of using recently developed high-power lasers for high-speed surface periodic structuring/patterning of the ceramic substrates for the subsequent thermal spray coating deposition, which may be difficult to pattern using conventional methods. Yttria-stabilized zirconia (YSZ) was selected as model ceramic for both substrates and coating. Three different types of patterns were produced by three different laser technologies: dimples with nominal depth of 15 and 30 µm (pulsed nanosecond laser), grids with nominal depth of 15 and 30 µm (continuous wave laser), and pillars with nominal depth 30 µm (ultrashort pulsed femtosecond laser). All surface patterns were thoroughly periodical and their surface roughness ranged from Sa = 4.5 to 10.3 µm, significantly surpassing conventional grit-blasting. Pulsed and continuous wave lasers showed very high process rates (up to 54.5 mm2/s and 323.6 mm2/s, respectively) and tendency to develop network of shallow surface cracks. Ultrashort pulsed laser technology was slower (process rate 1.65 mm2/s) but the surface was crack-free with desirable miniature anchoring points. Plasma spraying was carried out with powder, solution, and suspension feedstocks providing an experimental matrix demonstrating potential benefits and risks of each pattern-feedstock combination. Not all combinations led to successful coating deposition, but results show that microstructure of the coating may be deliberately controlled by laser texturing, in particular periodic substrate pattern led to periodic coating microstructure in the case of suspension spraying. Also adhesion/cohesion of the coating to the substrate may be in many cases significantly improved by laser patterning of the substrate. The highest coating adhesion/cohesion strength (26.2 ± 4.8 MPa) was achieved for the coating deposited from solution on pillar patterns. Finally, a possibility to combine the high-speed and advanced surface morphology produced by continuous wave and femtosecond lasers, respectively, and direct patterning of plasma sprayed coating were also demonstrated.
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From the scientific to the practical, stay on top of advances in this fast-growing coating technology with ASM International''s Journal of Thermal Spray Technology. Critically reviewed scientific papers and engineering articles combine the best of new research with the latest applications and problem solving.
A service of the ASM Thermal Spray Society (TSS), the Journal of Thermal Spray Technology covers all fundamental and practical aspects of thermal spray science, including processes, feedstock manufacture, and testing and characterization.
The journal contains worldwide coverage of the latest research, products, equipment and process developments, and includes technical note case studies from real-time applications and in-depth topical reviews.
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