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Splat morphology is an important factor that influences the mechanical properties and durability of thermal barrier coatings (TBCs). In this study, yttria-stabilized zirconia (YSZ) coatings with different lamellar interface morphologies were deposited by atmospheric plasma spraying (APS) using feedstocks with different particle sizes. The influence of lamellar interface roughness on the cracking resistance of the coatings was investigated. Furthermore, the thermal shock and erosion resistance of coatings deposited by two different powders was evaluated. It was found that the particle size of the feedstock powder affects the stacking morphology of the splat that forms the coating. Coatings fabricated from coarse YSZ powders (45-60 µm) show a relatively rough inter-lamellar surface, with a roughness about 3 times greater than those faricated from fine powders (15-25 µm). Coatings prepared with fine powders tend to form large cracks parallel to the substrate direction under indentation, while no cracking phenomena were found in coatings prepared with coarse powders. Due to the higher cracking resistance, coatings prepared with coarse powders show better thermal shock and erosion resistances than those with fine powders. The results of this study provide a reference for the design and optimization of the microstructure of TBCs.

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