A variety of yttria-stabilized zirconia (YSZ) coatings have been attained by plasma spray physical vapor deposition (PS-PVD) with fine YSZ powders at high power. The coating structures were found to change significantly with the powder feeding rates but less with the substrate temperature and the rate of the substrate rotation, and a porous feather like structure was attained at 500 Torr (666.6 millibar) and a rate of >200 lm/min. Such a coating produces porosity reaching >50%, thermal conductivity as small as 0.5 W/mK and lower infra-red transmittance compared to the sprayed splat coating with identical thickness.

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In this study, a variety of yttria-stabilized zirconia (YSZ) coatings have been obtained by plasma spray physical vapor deposition with fine powders at high power. The coating structures were found to change significantly with powder feed rate, but less with substrate temperature and rotation speed. Porous YSZ coatings with a feather-like structure and low thermal conductivity were deposited at rates as high as 220 μm/min. These results demonstrate the potential of plasma spray physical vapor deposition for producing thermal barrier coatings.