| abstract |
A method of manufacturing a substrate ( 16 ) with a ceramic thermal barrier coating ( 28, 32 ). The interface between layers of the coating contains an engineered surface roughness ( 12, 24 ) to enhance the mechanical integrity of the bond there between. The surface roughness is formed in a surface of a mold ( 10,20 ) and is infused by a subsequently cast layer of material ( 16, 28 ). The substrate may be partially sintered ( 76 ) prior to application of the coating layer(s) and the coated substrate and coating layer(s) may be co-sintered to form a fully coherent strain-free interlayer. |