This paper evaluates different techniques for measuring bond coat surface roughness, explores the influence of different thermal spray processes on the surface roughness of bond coats, and correlates bond coat surface roughness with spray parameters. The results of an evaluation of various techniques for measuring the surface roughness of the adhesive layer including the influence of the thermal spraying process, the powder size, the travel speed, and the coating thickness on the roughness of the thermal barrier coatings (TBCs) adhesive layers are presented. Light microscopy, a needle-tracking profile stylus, and non-contact interferometry with white light are used to characterize the adhesive layer surfaces. The results show that the measurement technique used had significant effects on some of the measured surface roughness values. Paper includes a German-language abstract.

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