The adhesion of aluminium–vitreous enamel cermets (dual phase vitreous enamels) coated onto steel substrates has been studied in detail. Electron metallography shows that excellent adhesion is associated with an ultrafine dispersion of α-Fe protrusions, which grow from the substrate into the glass. Identical features are observed with aluminium free coatings, indicating that adhesion is strongly influenced by mechanical interlocking, contrary to the currently favoured theoretical model. This model is explored in greater depth than has been done before, is shown to be incomplete, and a new description is put forward.
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