Effect of spraying power on the morphology of YSZ splat and micro-structure of thermal barrier coating

Abstract Yttria partially stabilized zirconia splats and their macroscopic thermal barrier coatings were prepared by atmospheric plasma spraying. And image analysis and scanning electron microscopy were adopted, together with splat as a link, to study why different pores and cracks are formed during the spraying process. It was determined that the spraying power altered the morphology of the splats, thereby affecting the macroscopic coating obtained by subsequent deposition. In the case where the power is too small, horizontal cracks and pores are more likely to occur, and when the power is too high, vertical cracks are likely to occur.