Abstract
Preoxidation of alloy substrates before spraying an oxide powder improves the adhesion of the coating. In the case of a low carbon steel (XC38) coated by plasma sprayed alumina, three preoxidation treatments in a classical furnace have been undertaken, in order to form respectively FeO, Fe3O4 and Fe2O3 layers. The best adhesion of alumina coating is obtained with FeO interlayers, and the worst with Fe2O3. The preliminary thermal treatment giving FeO implies a controlled atmosphere of carbon dioxide, but it points to some interesting prospects for coating complex parts. The origin of the improvement of adhesion may be a diffusion bonding at the FeO/Al2O3 interface or more simply it might be due to the increase of the substrate roughness with the time of oxidation. Besides, the epitaxial growth of FeO on steel probably explains the good mechanical resistance of the steel/FeO interface .
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