Enhanced interface adhesion by in-situ oxidation within metal-ceramic coatings

A new method for improving the adhesion of thermally sprayed metal-ceramic coatings is proposed. Experimental results show that an in-situ Al2O3 layer formed between the surface of a FeCrAl-ceramic coatings during the arc spraying rapid deposition and a hypoxic heat treatment, which it pinning in the FeCrAl bondcoat, significantly improving the bonding performance between metal and ceramic. Based on these experimental results, a new theory of in-situ oxidation-enhanced interfaces is proposed to explain the bonding between metal and ceramic coatings which can be improved after hypoxic heat treatment.