Dataset for Influence of Substrate Preparation on the Morphology and Mechanical Properties of Layered Al₂O₃/n-HAp Coatings on SS316L

This study investigates the effect of substrate preparation on the properties of multilayer Al2O3/n-HAp coatings on AISI 316L stainless steel deposited via flame spray coating. To improve hydroxyapatite adhesion, an Al2O3 bond coat was utilized following sandblasting with three abrasive mesh sizes: 16–30 (K), 30–60 (S), and 60–80 (H). Results revealed that surface topography significantly dictates splat dynamics and coating stability. The 30–60 mesh (S Specimen) specimen provided the most consistent performance, yielding an adhesion strength of 5.56±0.06 MPa and the lowest failure area (19.39%). Morphological analysis showed that coarser surfaces promote phase segregation and larger grain growth, whereas intermediate roughness facilitates more uniform mechanical interlocking. The findings suggest that a 30–60 mesh substrate preparation offers an optimal balance between mechanical reliability and the porous architecture required for bioactivity in orthopedic applications.