On nucleation and growth mechanisms of EBPVD zirconia films on porous NiO-ZrO₂ substrate

Thin structure of the anode-electrolyte interface (AEI) was studied, and plausible nucleation and growth mechanisms at electron-beam physical vapor deposition (EB-PVD) were established. ZrO₂ condensates with two mechanisms - planar and cellular ones like it happens at solidification from liquid phase. ZrO₂ condensation on ZrO₂ and NiO phases occurs with two different routes. On ZrO₂ phase, layer of planar growth is formed with 'defective layer by defective layer' mechanism. On NiO, the layer is cellular from the very beginning of the deposition process. The layer of planar growth is formed as 'dense layer by dense layer'. Deposition affected zone (DAZ) is clearly distinguished.