Abstract

Functionally graded ZrO2/NiCrAlY coatings are produced by detonation gun spraying using spheroid powers as the feedstock. A commercial Ni-based alloy is used for metallic substrate. The composition and microstructure are changed gradually through the six-layer graded coatings that are beneficial for the improvement of mechanical and thermal properties of the coatings. The shear test is carried out to analyze the interfacial bonding strengths of graded coatings. And non-graded duplex coatings are tested for comparative study. The effects of cross-sectional size and crosshead speed on interfacial strength properties are also studied. Results show that interfacial strengths of graded coatings are increased gradually with increase of volumetric rate of NiCrAlY. The bonding strength of the functionally graded coating is about twice as high as that of the duplex coating. For duplex coating without metallic interlayer and below 5 mm/min, the interfacial bonding strength of ZrO2/NiCrAlY interface increase with increasing crosshead speed.

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