To achieve sufficient adhesion strength within thermal spraying, the surface to be coated has to be modified. Grit blasting is the most common way to generate a clean and roughened surface. The bonding mechanism between the grit-blasted substrate and the coating is assumed to be due to mechanical anchoring, why an optimal surface roughness is essential. The surface roughness is usually evaluated using Ra which cannot fully characterize the complex nature of the chaotic substrate topography. This study was performed in order to evaluate if Ra can be replaced by other surface characteristic parameters such us RΔq, Rpk, Rpv, Rk…with higher correlation to adhesion strength. Average roughness was measured by a perthometer and with white light interferometry to get 3D images of the surface topography. Disc shaped substrate samples of Ti6Al4V (AMS 4928) were grit blasted with aluminium oxide grit and plasma sprayed with a Ni5%Al coating. Adhesion strength was determined according to the ASTM C633 standard. The correlation between a number of different surface-parameters and adhesion strength were evaluated and compared with Ra.

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