The suspension plasma spray (SPS) process was used to produce coatings from yttria-stabilized zirconia (YSZ) powders with median diameters of 15 lm and 80 nm. The powder-ethanol suspensions made with 15-lm diameter YSZ particles formed coatings with microstructures typical of the air plasma spray (APS) process, while suspensions made with 80-nm diameter YSZ powder yielded a coarse columnar microstructure not observed in APS coatings. To explain the formation mechanisms of these different microstructures, a hypothesis is presented which relates the dependence of YSZ droplet flight paths on droplet diameter to variations in deposition behavior. The thermal conductivity (k th ) of columnar SPS coatings was measured as a function of temperature in the as-sprayed condition and after a 50 h, 1200°C heat treatment. Coatings produced from suspensions containing 80 nm YSZ particles at powder concentrations of 2, 8, and 11 wt.% exhibited significantly different k th values. These differences are connected to microstructural variations between the SPS coatings produced by the three suspension formulations. Heat treatment increased the k th of the coatings generated from suspensions containing 2 and 11 wt.% of 80 nm YSZ powder, but this k th increase was less than has been observed in APS coatings.

Additive manufacturing of near‐net‐shaped dense ceramic components has been established via room‐temperature direct writing of highly loaded aqueous alumina suspensions in a layer‐by‐layer fashion. The effect of alumina solid loading on rheology, specimen uniformity, density, microstructure, and mechanical properties was studied. All suspensions contained a polymer binder (~5 vol.%), dispersant, and 51–58 vol.% alumina powder. Rheological measurements indicated all suspensions to be yield‐pseuodoplastic, and both yield stress and viscosity were found to increase with increasing alumina solid loading. Shear rates ranging from 19.5 to 24.2/s, corresponding to viscosities of 9.8 to 17.2 Pa·s, for the 53–56 vol.% alumina suspensions were found to produce the best results for the 1.25‐mm tip employed during writing. All parts were sintered to >98% of true density, with grain sizes ranging from 3.2 to 3.7 μm. The average flexure strength, which ranged from 134 to 157 MPa, was not influenced by the alumina solid loading.

Fibrous monolithic ceramics are an example of a laminate in which a controlled, three-dimensional structure has been introduced on a submillimeter scale. This unique structure allows this all-ceramic material to fail in a nonbrittle manner. Materials have been fabricated and tested with a variety of architectures. The influence on mechanical properties at room temperature and at high temperature of the structure of the constituent phases and the architecture in which they are arranged are discussed. The elastic properties of these materials can be effectively predicted using existing models. These models also can be extended to predict the strength of fibrous monoliths with an arbitrary orientation and architecture. However, the mechanisms that govern the energy absorption capacity of fibrous monoliths are unique, and experimental results do not follow existing models. Energy dissipation occurs through two dominant mechanisms-delamination of the weak interphases and then frictional sliding after cracking occurs. The properties of the constituent phases that maximize energy absorption are discussed.

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