The bonding of thermal-sprayed coatings largely depends on the substrate surface morphology. This study examines the effect of the substrate surface texture shapes on the adhesion strength of coatings. For that, it used plasma-sprayed Ni-based MoS2 coatings deposited on grit-blasted and laser-textured surfaces, and investigated the coating bonding strength (ASTM 633 pull-off test), and cross-sectional and fracture morphologies, as well as phase compositions and element distribution. The results showed that the surface texture shape has a significant effect on the improvement of coating adhesion. The coatings deposited on sinusoidal-textured surfaces had the highest adhesion strength (50.0 MPa), followed by coatings deposited on groove-textured surfaces, while dimple and dimple–groove textures resulted in the lowest coating adhesion strength. The coating fracture analysis revealed that cohesive failure occurred mainly at the texture positions, while adhesive failure occurred almost always in plain areas. Therefore, it could be concluded that, in the conditions of this study, the existence of plain areas and dimple textures did not improve coating adhesion. Factors such as coating bond mode, contact area ratio, and coating deposition quality should be comprehensively considered in texture design to improve coating adhesion.

中文翻译：

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基材表面纹理形状对等离子喷涂镍基涂层附着力的影响

热喷涂涂层的粘合很大程度上取决于基材表面形态。本研究考察了基材表面纹理形状对涂层附着强度的影响。为此，它使用了沉积在喷砂和激光纹理表面上的等离子喷涂 Ni 基 MoS2 涂层，并研究了涂层结合强度（ASTM 633 拉断测试）、横截面和断裂形态，以及相组成和元素分布。结果表明，表面织构形状对涂层附着力的提高有显着影响。沉积在正弦纹理表面的涂层具有最高的粘附强度（50.0 MPa），其次是沉积在凹槽纹理表面的涂层，而凹坑和凹坑-凹槽纹理导致涂层粘附强度最低。涂层断裂分析表明，内聚破坏主要发生在纹理位置，而粘合破坏几乎总是发生在平原区域。因此，可以得出结论，在本研究的条件下，平面区域和凹痕纹理的存在并没有提高涂层附着力。纹理设计应综合考虑涂层结合方式、接触面积比、涂层沉积质量等因素，提高涂层附着力。