Laser-Grooved Ceramic Surface for Uniform Coating Adhesion
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Solution Overview
Problem
Ceramic substrates face challenges in achieving uniform filling and strong adhesion of surface treatment materials due to limitations in groove formation and oxide film formation during laser treatment, which affects their oxidation and corrosion resistance.
Innovation Solution
A laser treatment method that creates grooves with specific aspect ratios and opening ratios on ceramic substrates, allowing for uniform filling and enhanced adhesion of thermal sprayed materials, while preventing oxide film formation and ensuring effective roughening of inter-groove areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a laser treatment is performed to form grooves on a ceramic substrate to enhance adhesion of surface treatment materials, then the adhesion strength is improved, but oxide films are formed on the ceramic member which degrades quality and limits utilization
Solution Approach 1:
The patent applies inert atmosphere by performing laser treatment in an atmosphere containing 5% or more of a non-oxidizable gas (such as nitrogen or rare gases). This inert environment prevents oxidation of the ceramic substrate during laser processing, avoiding oxide film formation while maintaining groove structures for enhanced adhesion of surface treatment materials.
2Strength
If grooves are formed with deep depth to enhance adhesion, then the adhesion strength is improved, but the grooves cannot be uniformly filled with surface treatment materials
Solution Approach 1:
The patent applies parameter changes by optimizing the aspect ratio of grooves to be 0.5 or more and 1.3 or less. This specific parameter range ensures that grooves are deep enough to provide anchoring effect for strong adhesion, while maintaining a geometry that allows uniform filling with surface treatment materials during thermal spraying or other coating processes.
3Manufacturing precision
If the pitch between adjacent grooves is increased to allow uniform filling, then the filling uniformity is improved, but the surface area for adhesion is reduced
Solution Approach 1:
The patent applies parameter changes by optimizing the pitch between adjacent grooves to be within a specific range that balances two requirements: sufficient spacing to allow uniform filling of grooves with surface treatment materials, and adequate density to maintain large total surface area for strong adhesion. The optimized pitch ensures both uniform filling and high adhesion strength.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enables ceramic members to achieve strong adhesion with surface treatment materials, maintaining high tensile adhesion strength and preventing oxide film formation, thus enhancing their oxidation and corrosion resistance.
Implementation Method 1
a surface of a ceramic substrate is irradiated with a laser to provide a plurality of grooves
Data Source
AI summary
A ceramic member is produced by performing a laser treatment on a ceramic substrate as a pretreatment for a surface treatment such that grooves that can be substantially uniformly filled with a surface treatment material are formed in the surface of the ceramic substrate. Through laser irradiation of the surface, grooves with recessed surfaces formed to extend in at least one direction are provided. Flat surfaces are formed at areas between the grooves that are adjacent to each other. Pitches between the adjacent grooves are set to a range of 0.05 mm to 0.30 mm. One of the grooves has a width that progressively decreases as the depth increases and is opened on one side in the depth direction at a maximum width. The one of the grooves has an aspect ratio in a range of 0.5 to 1.3 and an opening ratio of equal to or greater than 70%.