Feather-Like Structured YSZ Coatings at Fast Rates by Plasma Spray Physical Vapor Deposition

Abstract

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.