Formation of splats from hollow YSZ droplets deserves a special attention for thermal spraying. In this case, immediately prior to particle – substrate collision, we have a drop that consists of a liquid shell enclosing a gas cavity heated to a temperature close to the melt temperature. As the drop impinges onto the substrate, it suffers considerable deformation resulting in a rise of the gas pressure and in a decrease of gas temperature. The paper presented includes the results of the model experiments carried out under full control of the key physical parameters (KPPs) - temperature, velocity and size of droplet, and temperature of polished substrate, in which the starting powder was a specially prepared powder consisting exclusively of the hollow spherical YSZ particles. The main goal of the paper is to discuss and study the possible splat formation scenarios under above-mentioned conditions.

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