Characterization of air plasma-sprayed yttria-stabilized zirconia coatings deposited with nitrogen

Abstract

Air plasma-sprayed (APS) yttria-stabilized zirconia (YSZ) conventional and nanostructured coatings were deposited with nitrogen as the primary plasma gas. Nanostructured coatings were deposited as a function of critical plasma spray parameter (CPSP). Microstructural characteristics, e.g., phase distribution, porosity, microhardness, percentage of partially melted (PM) regions, surface roughness, and wear performance, were evaluated for deposited coatings. Effect of CPSP on wear performance of coatings was most prominent at highest normal load considered. Conventional and nanostructured coatings deposited with nitrogen showed different trends for specific wear rate as a function of normal load. While specific wear rate for conventional coatings was nearly constant, it increased with increasing load for nanostructured coatings. Thus, even though nanostructured coatings provided better wear resistance at lower normal loads, conventional YSZ coatings become more wear resistant at higher loads. For example, at highest normal load considered, specific wear rate of conventional coatings was around 12 % smaller than that for corresponding nanostructured coatings.