Abstract
The scope of sol-gel methods for preparing plasma spray powders has been extended by developing a technique in which small amounts of aqueous sols are made to carry particulate material and then gelled and fired to yield free-flowing spherical particles. This concept is illustrated by the use of ZrO 2 sol as the “vehicle” and Cr 2O 3, Al 2O 3 and MgO as the “passengers”. The spraying characteristics of the resultant materials have been compared with those of some commercially available powders, as have selected properties of the coatings subsequently deposited. Superior deposit efficiency, higher bond strength and impact resistance have been observed. Further, the presence of the ZrO 2 binder appears partially to suppress the vapour pressure of the volatile oxides.
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