Laser additive modification: a technique for directional ceramization of metal surfaces

Ceramic-reinforced metal materials are indispensable in industrial equipment such as aircraft engines and nuclear reactors, but the difference in coefficient of thermal expansion (CTE) between ceramics and metals limits the service life of ceramic films. The fabrication of transition layers between metal and ceramic films is a common solution strategy, but the process is inevitably complicated, costly, and material-restricted. Here, we use a high-energy laser beam to impact ceramic nanoparticles to modify the metal surface and ultimately harmonize the thermophysical properties at the interface between the substrate and ceramic film. The test results show that the superalloy substrate modified by ZrC and 8YSZ laser additive is favorable for L-YSZ bonding, while the superalloy substrate modified by Al₂O₃ is favorable for Al₂O₃ thin film bonding, and the interfacial adhesion of L-YSZ and Al₂O₃ films was improved by more than 3.6 and 9 folds, respectively.