The Influence of the Irregular Interface Geometry on Fracture of EB-PVD Yttria-Stabilized Zirconia Coatings.

The analysis of images of the top and side surfaces of 3D-printed Ti–6Al–4V specimens with yttria-stabilized zirconia (YSZ) coatings deformed to different degree in uniaxial tension reveals regularities of cracking and spallation of ceramic coatings depending on the interface geometry. The surface roughness of 3D-printed specimens is varied by the electron beam treatment or mechanical grinding and polishing. It is shown that the corrugated relief formed at the surface of 3D-printed specimens prevents thermal barrier YSZ coatings from spallation and delamination under mechanical loading. [ABSTRACT FROM AUTHOR]