Surface roughening of Al2O3/Al2O3-ceramic matrix composites by nanosecond laser ablation prior to thermal spraying

Al2O3/Al2O3 ceramic matrix composites are candidate materials for high-temperature applications such as gas turbines. As water vapor corrosion of Al2O3/Al2O3-CMC (ceramic matrix composite) is a major issue, the application of suitable environmental barrier coatings is inevitable. An important factor for coating adhesion, especially in thermal spraying, is mechanical interlocking. Therefore, a rough substrate surface is needed. Although it has been proven that laser ablation is a suitable method for surface preparation of metallic substrates, no studies on Al2O3/Al2O3-CMCs are available. Therefore, the suitability of surface preparation of an Al2O3/Al2O3-CMC by laser ablation for use prior to atmospheric plasma spraying was examined. The laser ablation threshold fluence for Al2O3/Al2O3-CMC was determined. The effects of different processing parameters on the surface were studied. Various surface morphologies were obtained, such as cauliflower and honeycomb structures. The samples were characterized by white light interferometry, laser microscopy, and scanning electron microscopy. The obtained surface structures were coated with Gd2Zr2O7. It was found that the adhesion strength of coatings on laser treated samples was drastically increased.