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Over the last decade there has been an explosion in terms of available tools for sensing the particle spray stream in thermal spray processes. This has led to considerable enhancement in our understanding of process reproducibility and reliability. Despite these advances, the linkage to coating properties has continued to be an enigma. This is partially due to the complex nature of the build-up process and the associated issues with measuring properties of these complex coatings. In this paper, we identify critical issues in processing-structure-property relations particularly with respect to the linkage to particle properties. Our goal is to demonstrate an integrated strategy, one that combines particle state sensing, with process mapping and extracting coating properties in situ through the development of robust and advanced curvature-based techniques. These techniques allow estimation of coating modulus, residual stress and, non-linear response of thermal sprayed ceramic coatings all within minutes of the deposition process. Finally, the integrated strategy examines the role of process maps for control of the spray stream as well as tailoring properties of thermal spray coatings. Examples of such studies for yttria-stabilized zirconia thermal barrier coatings are discussed.

Plasma sprayed coatings of Yttria Stabilized Zirconia (YSZ) have been studied extensively through the years to understand variations in coating properties as well as to achieve control on microstructure of the coatings. The requirement for microstructural control and reliability have become all the more important as coatings have now become part of an integrated "prime reliant" design strategy aimed at increasing turbine inlet temperature and associated efficiencies. One of the important thrusts in monitoring and controlling the process has been the application of process sensors that measure spray stream characteristics, notably particle temperature and velocity. Although single particle-based measurements have been available for some time, in general control strategies based on particle state rely on average values of temperature and velocity. In this study, a detailed examination of particle temperature distributions is presented. When systematically examined over a wide range of operating conditions of the resulting range of particle temperatures, a significant structure in the statistical distribution has been observed. A close inspection of the data indicates that this distribution can be interpreted as melting state indicator for YSZ. A characteristic peak at the melting point of ZrO 2 (error in absolute T -measurement is ≈ ±10%) can be used as an indicator for re-solidified particles. In the past, control strategies based on process diagnostic sensors have been based on average particle temperatures and velocities. Although the average values seem to be promising as control parameters, it has been shown through our results that different melting states could be demonstrated for the same average T and V settings. The melting state in turn has an important bearing on the coating structure and properties. It therefore implies that a process control strategy (to maintain coating quality) based on in flight particle sensors will have to take these findings into account. As an example, one strategy of process control would not only define the process in terms of the average particle temperature and velocity but also include the effect that parameter changes have on distributions.

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