Controllable melt-flow-driven laser texturing for predictable interfacial adhesion of YSZ coatings on superalloys

Thin-film materials are widely used in critical systems such as flexible electronics, aerospace, and military components. However, their adhesion energy is often compromised by particulate erosion and thermal cycling, mainly due to mismatched thermal expansion. This study employs precisely controlled laser-induced melt flow to fabricate hierarchical micro-nano textured surfaces. This process is guided by a predictive framework that overlays substrate phase diagrams with film morphology maps. The credibility of this framework is corroborated by tape-peel retention data, nanoscratch adhesion measurements, and a coupled theoretical predictor. Experiments reveal a trade-off between contact area and defect density controlled by surface textures. Optimized textures significantly enhance both thermal cycle life and adhesion energy, as validated by nanoscratch testing. This approach offers a new strategy for designing robust thermal barrier coatings with enhanced durability under thermal and mechanical loads.