Three adhesion measurement methods for thermal spray coatings, namely tensile adhesive strength (according to EN 582), interfacial indentation and in-plane tensile tests were investigated in terms of accuracy of the results and application potential for different coating / substrate conditions. Whereas the tensile adhesive strength test is widely used in industry, the other two methods are still under development in research laboratories and therefore only few experimental data on the accuracy of the methods and on the potential in an industrial context are available. For that reason, dissimilar coating-substrate combinations covering a wide range of types of thermal spray coating-substrate systems were tested using all these methods. Ceramic (Al2O3) and metallic (NiCr 80-20) coatings were thermally sprayed by flame spraying with two different thickness on titanium alloy and steel substrates exhibiting each two distinct roughness levels. The distinguished coating properties include the coating toughness, shear strength, interfacial toughness, and adhesive strength. Thermally sprayed coatings do not only show an interfacial complexity, but also the integrity of the interface of substrate and coating has to be considered, as well as porosity, cracks and residual stresses. In this paper, each measurement method was found to be related to certain type of loading conditions and fracture mode. The results of the different methods are compared and the limits of applicability of the different methods are discussed.

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