{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2026,9,12]],"date-time":"2026-09-12T05:07:17Z","timestamp":1789189637166,"version":"build-2803163510"},"reference-count":27,"publisher":"MDPI AG","issue":"18","license":[{"start":{"date-parts":[[2026,9,10]],"date-time":"2026-09-10T00:00:00Z","timestamp":1788998400000},"content-version":"vor","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0\/"}],"funder":[{"DOI":"10.13039\/501100012190","name":"Ministry of Science and Higher Education","doi-asserted-by":"crossref","id":[{"id":"10.13039\/501100012190","id-type":"DOI","asserted-by":"crossref"}]},{"id":[{"id":"https:\/\/ror.org\/05dwvd537","id-type":"ROR","asserted-by":"publisher"}]}],"content-domain":{"domain":[],"crossmark-restriction":false},"short-container-title":["Materials"],"abstract":"<jats:p>The surface condition of the bond coat is an important factor governing the growth and microstructural development of electron-beam physical vapour deposition (EB-PVD) TBCs. In this study, 7 wt.% yttria-stabilised zirconia (7YSZ) coatings were deposited by EB-PVD on vapour-phase aluminide bond coats with three distinct surface conditions, ranging from the as-coated state to ground and polished surfaces. The effect of bond coat roughness was evaluated through surface profilometry, scanning electron microscopy, X-ray diffraction, quantitative analysis of columnar architecture and porosity, scratch testing, and Vickers microindentation. Reducing the bond coat roughness resulted in a more uniform columnar architecture, reduced intercolumnar spacing, and a lower degree of column inclination, accompanied by a decrease in the coating surface roughness. XRD confirmed the formation of the expected tetragonal\/cubic 7YSZ phase assemblage for all investigated conditions. Scratch testing revealed no delamination or spallation up to the maximum applied load of 200 N, indicating high interfacial integrity irrespective of bond coat roughness. Vickers measurements revealed a statistically significant through-thickness hardness gradient for all coatings, with hardness decreasing from the bond coat interface towards the column tips. Importantly, bond coat roughness had no statistically significant effect on hardness near the interface or in the central region, whereas significant differences were observed near the column tips. These results demonstrate that bond coat roughness strongly governs EB-PVD columnar architecture and surface morphology, while its influence on hardness is predominantly confined to the uppermost region of the coating.<\/jats:p>","DOI":"10.3390\/ma19183857","type":"journal-article","created":{"date-parts":[[2026,9,10]],"date-time":"2026-09-10T13:04:57Z","timestamp":1789045497000},"page":"3857","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":0,"title":["Influence of Bond Coat Roughness on the Microstructure and Mechanical Properties of EB-PVD TBCs"],"prefix":"10.3390","volume":"19","author":[{"ORCID":"https:\/\/orcid.org\/0000-0003-3889-6597","authenticated-orcid":false,"given":"Grzegorz","family":"Maciaszek","sequence":"first","affiliation":[{"name":"Faculty of Mechanical Engineering and Aeronautics, Rzesz\u00f3w University of Technology, 35-959 Rzesz\u00f3w, Poland"}],"role":[{"vocabulary":"crossref","role":"author"},{"role":"conceptualization","vocabulary":"credit"},{"role":"methodology","vocabulary":"credit"},{"role":"software","vocabulary":"credit"},{"role":"validation","vocabulary":"credit"},{"role":"formal-analysis","vocabulary":"credit"},{"role":"writing-review-editing","vocabulary":"credit"},{"role":"writing-original-draft","vocabulary":"credit"}]},{"ORCID":"https:\/\/orcid.org\/0000-0001-7620-776X","authenticated-orcid":false,"given":"Andrzej","family":"Nowotnik","sequence":"additional","affiliation":[{"name":"Faculty of Mechanical Engineering and Aeronautics, Rzesz\u00f3w University of Technology, 35-959 Rzesz\u00f3w, Poland"}],"role":[{"vocabulary":"crossref","role":"author"},{"role":"conceptualization","vocabulary":"credit"},{"role":"methodology","vocabulary":"credit"},{"role":"validation","vocabulary":"credit"},{"role":"investigation","vocabulary":"credit"},{"role":"writing-review-editing","vocabulary":"credit"},{"role":"writing-original-draft","vocabulary":"credit"},{"role":"funding-acquisition","vocabulary":"credit"},{"role":"project-administration","vocabulary":"credit"},{"role":"visualization","vocabulary":"credit"},{"role":"supervision","vocabulary":"credit"}]},{"ORCID":"https:\/\/orcid.org\/0009-0001-9054-2879","authenticated-orcid":false,"given":"Julia","family":"Maciaszek","sequence":"additional","affiliation":[{"name":"Faculty of Mechanical Engineering and Aeronautics, Rzesz\u00f3w University of Technology, 35-959 Rzesz\u00f3w, Poland"}],"role":[{"vocabulary":"crossref","role":"author"},{"role":"writing-review-editing","vocabulary":"credit"},{"role":"writing-original-draft","vocabulary":"credit"},{"role":"methodology","vocabulary":"credit"},{"role":"investigation","vocabulary":"credit"}]}],"member":"1968","published-online":{"date-parts":[[2026,9,10]]},"reference":[{"key":"ref_1","doi-asserted-by":"crossref","first-page":"2240007","DOI":"10.1142\/S0218625X22400078","article-title":"Thermal Barrier Coatings: Recent Developments, Challenges, and Probable Solutions","volume":"32","author":"Prashar","year":"2025","journal-title":"Surf. Rev. Lett."},{"key":"ref_2","doi-asserted-by":"crossref","first-page":"6061","DOI":"10.1021\/acs.iecr.1c00788","article-title":"Thermal Barrier Coatings Overview: Design, Manufacturing, and Applications in High-Temperature Industries","volume":"60","author":"Mondal","year":"2021","journal-title":"Ind. Eng. Chem. Res."},{"key":"ref_3","doi-asserted-by":"crossref","unstructured":"Evans, A.G., Mumm, D.R., Hutchinson, J.W., Meier, G.H., and Pettit, F.S. (2001). Mechanisms controlling the durability of thermal barrier coatings. Prog. Mater. Sci., 46.","DOI":"10.1016\/S0079-6425(00)00020-7"},{"key":"ref_4","doi-asserted-by":"crossref","first-page":"1095","DOI":"10.1126\/science.1068609","article-title":"Thermal Barrier Coatings for Gas-Turbine Engine Applications","volume":"296","author":"Padture","year":"2002","journal-title":"Science"},{"key":"ref_5","doi-asserted-by":"crossref","first-page":"383","DOI":"10.1016\/S0257-8972(01)01651-6","article-title":"Methods to reduce the thermal conductivity of EB-PVD TBCs","volume":"151\u2013152","author":"Nicholls","year":"2002","journal-title":"Surf. Coat. Technol."},{"key":"ref_6","doi-asserted-by":"crossref","first-page":"449","DOI":"10.1016\/j.surfcoat.2008.08.056","article-title":"Cyclic behavior of EB-PVD thermal barrier coating systems with modified bond coats","volume":"203","author":"Schulz","year":"2008","journal-title":"Surf. Coat. Technol."},{"key":"ref_7","doi-asserted-by":"crossref","first-page":"117274","DOI":"10.1016\/j.jeurceramsoc.2025.117274","article-title":"A review on the performance and lifetime improvement of thermal barrier coatings","volume":"45","author":"Sezavar","year":"2025","journal-title":"J. Eur. Ceram. Soc."},{"key":"ref_8","doi-asserted-by":"crossref","unstructured":"Peng, H., and Gong, S. (2023). Thermal barrier coatings prepared by electron beam-physical vapor deposition (EB-PVD). Thermal Barrier Coatings, Woodhead Publishing.","DOI":"10.1016\/B978-0-12-819027-2.00002-X"},{"key":"ref_9","doi-asserted-by":"crossref","first-page":"377","DOI":"10.4028\/www.scientific.net\/SSP.227.377","article-title":"The Technology of TBC Deposition by EB-PVD Method","volume":"227","author":"Nowotnik","year":"2015","journal-title":"Solid State Phenom."},{"key":"ref_10","doi-asserted-by":"crossref","first-page":"259","DOI":"10.1016\/0257-8972(95)02727-0","article-title":"EB-PVD Y2O3- and CeO2Y2O3-stabilized zirconia thermal barrier coatings\u2014Crystal habit and phase composition","volume":"82","author":"Schulz","year":"1996","journal-title":"Surf. Coat. Technol."},{"key":"ref_11","doi-asserted-by":"crossref","unstructured":"Gong, S., and Wu, Q. (2011). Processing, microstructures and properties of thermal barrier coatings by electron beam physical vapor deposition (EB\u2013PVD). Thermal Barrier Coatings, Woodhead Publishing.","DOI":"10.1533\/9780857090829.2.115"},{"key":"ref_12","doi-asserted-by":"crossref","first-page":"2064","DOI":"10.1016\/j.surfcoat.2009.02.008","article-title":"Thermal barrier coating systems\u2014Analysis of nanoindentation curves","volume":"203","author":"Zotov","year":"2009","journal-title":"Surf. Coat. Technol."},{"key":"ref_13","doi-asserted-by":"crossref","first-page":"75","DOI":"10.1016\/S0257-8972(02)00594-7","article-title":"Determination of mechanical properties of electron beam-physical vapor deposition-thermal barrier coatings (EB-PVD-TBCs) by means of nanoindentation and impact testing","volume":"163\u2013164","author":"Bouzakis","year":"2003","journal-title":"Surf. Coat. Technol."},{"key":"ref_14","doi-asserted-by":"crossref","first-page":"1744","DOI":"10.1111\/j.1744-7402.2004.tb00182.x","article-title":"Review on Advanced EB-PVD Ceramic Topcoats for TBC Applications","volume":"1","author":"Schulz","year":"2004","journal-title":"Int. J. Appl. Ceram. Technol."},{"key":"ref_15","doi-asserted-by":"crossref","first-page":"129095","DOI":"10.1016\/j.surfcoat.2022.129095","article-title":"The behavior of plasma sprayed thermal barrier coating with laser microtextured bond coat under high temperature testing","volume":"453","author":"Sokolowski","year":"2023","journal-title":"Surf. Coat. Technol."},{"key":"ref_16","doi-asserted-by":"crossref","unstructured":"Xie, Z., Liu, Q., Lee, K.-I., Zhu, W., Wu, L.T., and Wu, R.T. (2022). The Effect of Bond Coat Roughness on the CMAS Hot Corrosion Resistance of EB-PVD Thermal Barrier Coatings. Coatings, 12.","DOI":"10.3390\/coatings12050596"},{"key":"ref_17","doi-asserted-by":"crossref","first-page":"132026","DOI":"10.1016\/j.surfcoat.2025.132026","article-title":"Effect of interface roughness on the CMAS + molten salt (Na2SO4 + NaCl + NaVO3) corrosion resistance of EB-PVD thermal barrier coatings","volume":"503","author":"Hu","year":"2025","journal-title":"Surf. Coat. Technol."},{"key":"ref_18","doi-asserted-by":"crossref","first-page":"3462","DOI":"10.1016\/j.matlet.2005.06.014","article-title":"Influence of porosity on hardness and Young\u2019s modulus of nanoporous EB-PVD TBCs by nanoindentation","volume":"59","author":"Jang","year":"2005","journal-title":"Mater. Lett."},{"key":"ref_19","doi-asserted-by":"crossref","first-page":"79","DOI":"10.1016\/j.surfcoat.2004.08.018","article-title":"Nano and microhardness testing of aged EB PVD TBCs","volume":"188\u2013189","author":"Wellman","year":"2004","journal-title":"Surf. Coat. Technol."},{"key":"ref_20","doi-asserted-by":"crossref","first-page":"143","DOI":"10.1016\/j.surfcoat.2012.06.045","article-title":"Microstructural studies on EB-PVD deposited NiCrAlY, YSZ and lanthanum zirconate for thermal barrier applications","volume":"207","author":"Mishra","year":"2012","journal-title":"Surf. Coat. Technol."},{"key":"ref_21","doi-asserted-by":"crossref","first-page":"262","DOI":"10.1016\/j.surfcoat.2018.11.055","article-title":"Evaluation of oxidation and thermal cyclic behavior of YSZ, Gd2Zr2O7 and YSZ\/Gd2Zr2O7 TBCs","volume":"371","author":"Doleker","year":"2019","journal-title":"Surf. Coat. Technol."},{"key":"ref_22","doi-asserted-by":"crossref","first-page":"4686","DOI":"10.1007\/s11665-016-2328-5","article-title":"Phase Transformation and Lattice Parameter Changes of Trivalent Rare Earth Doped YSZ as a Function of Temperature","volume":"25","author":"Jiang","year":"2016","journal-title":"J. Mater. Eng. Perform."},{"key":"ref_23","doi-asserted-by":"crossref","first-page":"7360","DOI":"10.1016\/j.ceramint.2016.01.138","article-title":"Phase stability and thermal conductivity of RE2O3 (RE = La, Nd, Gd, Yb) and Yb2O3 co-doped Y2O3 stabilized ZrO2 ceramics","volume":"42","author":"Guo","year":"2016","journal-title":"Ceram. Int."},{"key":"ref_24","doi-asserted-by":"crossref","first-page":"110576","DOI":"10.1016\/j.vacuum.2021.110576","article-title":"Comparison of calcium\u2013magnesium-alumina-silicate (CMAS) resistance behavior of produced with electron beam physical vapor deposition (EB-PVD) method YSZ and Gd2Zr2O7\/YSZ thermal barrier coatings systems","volume":"194","author":"Ozgurluk","year":"2021","journal-title":"Vacuum"},{"key":"ref_25","doi-asserted-by":"crossref","first-page":"6519","DOI":"10.1016\/j.actamat.2011.06.018","article-title":"Damage evolution and rupture time prediction in thermal barrier coatings subjected to cyclic heating and cooling: An acoustic emission method","volume":"59","author":"Yang","year":"2011","journal-title":"Acta Mater."},{"key":"ref_26","doi-asserted-by":"crossref","first-page":"263","DOI":"10.1016\/j.ceramint.2005.01.018","article-title":"Effect of thermal exposure on hardness and Young\u2019s modulus of EB-PVD yttria-partially-stabilized zirconia thermal barrier coatings","volume":"32","author":"Guo","year":"2006","journal-title":"Ceram. Int."},{"key":"ref_27","doi-asserted-by":"crossref","first-page":"440","DOI":"10.1016\/j.jmst.2018.09.046","article-title":"Comparison of CMAS corrosion and sintering induced microstructural characteristics of APS thermal barrier coatings","volume":"35","author":"Wu","year":"2019","journal-title":"J. Mater. Sci. Technol."}],"container-title":["Materials"],"original-title":[],"language":"en","link":[{"URL":"https:\/\/www.mdpi.com\/1996-1944\/19\/18\/3857\/pdf","content-type":"unspecified","content-version":"vor","intended-application":"similarity-checking"}],"deposited":{"date-parts":[[2026,9,12]],"date-time":"2026-09-12T04:35:53Z","timestamp":1789187753000},"score":1,"resource":{"primary":{"URL":"https:\/\/www.mdpi.com\/1996-1944\/19\/18\/3857"}},"subtitle":[],"short-title":[],"issued":{"date-parts":[[2026,9,10]]},"references-count":27,"journal-issue":{"issue":"18","published-online":{"date-parts":[[2026,9]]}},"alternative-id":["ma19183857"],"URL":"https:\/\/doi.org\/10.3390\/ma19183857","relation":{},"ISSN":["1996-1944"],"issn-type":[{"value":"1996-1944","type":"electronic"}],"subject":[],"published":{"date-parts":[[2026,9,10]]}}}