Initial Stages in Zirconia Coatings Using ESD

Abstract

International audienceThis study describes the phenomena occurring during the first stages of layer formation in the ESD (electrostatic spray deposition) process. Solutions containing zirconyl nitrate dissolved in a mixture of butyl carbitol−water−ethanol (40:40:20 vol %) have been sprayed on heated glass substrates. The spreading and drying of the droplets and the growth of the coating over a time range of 10 s to 10 min have been studied using SEM and optical microscopy. The influence of the substrate temperature, concentration of the salts, nature, and concentration of polymer additives on the microstructure of the deposited coatings has been studied. This work shows that there is little connection between the evolution of the droplets spreading and the final microstructure of the coating. This is due to the strong effect of the preferential landing and to the presence of a liquid layer at the surface of the coating during the deposition process. These results will contribute to the understanding of the coating formation in the ESD technique. They will finally help to synthesize finely controlled thin layers of zirconia for direct applications as SOFC electrolytes

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