Impact of cathode loss on plasma characteristics, microstructures and properties of 7YSZ coatings in PS-PVD

Abstract The slight changes in geometry and mass of the cathode of O3CP plasma torch during service life caused the variety of arc motion between the cathode and anode. The voltage appeared to rise first and then fall. In this experiment, the impact of cathode loss on plasma characteristics, microstructures and properties of 7YSZ coatings was investigated. Optical emission spectroscopy (OES) was used to characterize the plasma jet characteristics such as plasma temperature and electron number density. It is found that vapor deposition is the main deposition mechanism, and the microstructures of the coatings are mainly affected by the supersaturation and subcooling of the vapor phase, which determine the nucleation and growth of crystals. At the middle of cathode service life, the plasma temperature and electron number density are the highest and the powder is completely evaporated. High crystal growth rates and surface diffusion lead to large columnar crystals with large grain size. The best thermal shock resistance. The thermal shock resistance is the best in this case. When the cathode is in the beginning and end of service life, there are columnar grains with small size produced and many solid particles in the gaps due to diffusion difficulties generated by low temperature. Shadowing enhances to manufacture fine grains and few branches. The presence of solid particles prevents the release of thermal stress and reduces thermal shock resistance of coatings. Fine grains prevent cracks propagation to improve the bonding strength of coatings.