| This paper discuss on the joining of Ni-alloy and oxi- de-ceramic material on aluminium piston by plasma spray- ing. By searching the skill of surface, and intrducing the gradient technology, I continue to select plasma sp- raying to make the graded heat barrier coating. The eff- ect of graded layer number , graded thickness and compo- sitional gradient exponent on thermal residual stresses value and distribution was analyzed, then several param- eters were optimized. Many ceramics were comprised, and the demands of piston working were thought, I seleccted 8% Y203 stabilized Zr02 to make the gradient thermal ba- rrier coating with NiCrAICoY. Many experiments were done, the results made known th- at all kinds of the performance of the gradient coating was excellent. On this foundation, using met allographi? cal microscope, stereoscan electronic probe and energy analysis instrument, etc. to analyize the associative w? ay of the coating. In the end, I think chemical bonds w- ere formed between the oxideeramic and the Nilloy. Because of this and the introducing of the gradient tec? hnology, the bonding strength of the graded coating was increased a lot. It is a new train of thought for the d? esolving of thermal barrier coating?s reliability.
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