Abstract
The properties of coating materials can be improved via microstructural design. This study proposed a structure control strategy for plasma sprayed YSZ coatings. A non-conventional powder feeding method was used to controllably embed second-phase particles into a conventional coating matrix during plasma splaying, that is, two types of powder were fed at two specific locations into the plasma jet whereby producing a controlled composite thermal barrier coating (TBC) comprising a conventional coating matrix containing porous micro-agglomerated particles. Properties improvements can be attributed to this new structure. The thermal insulation ability, anti-sintering properties and thermal shock resistance of the novel TBC were superior to conventional TBCs. This structure control strategy provided a new approach to the design and development of advanced coatings and shows great promise for application in next generation thermal barrier coatings.
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