Calcium zirconate and magnesium zirconate prepared by synthesis and agglomeration were sprayed using a water stabilized plasma gun under varied spraying conditions. The same set of conditions was maintained during spraying of fused lime stabilized zirconia and magnesia stabilized zirconia. The intent of the study was to compare spraying behaviour and deposit properties of pairs of feedstock material that have just about the same chemical composition but differ considerably in the way of preparation. Free-flight particles as well as deposits were characterised by standard techniques, such as light microscopy, scanning electron microscopy with energy-dispersive spectroscopy, X-ray diffraction, differential thermal analysis, and pycnometry. The differences between relevant coatings were evaluated namely in terms of morphology, chemical and phase composition, density and porosity. Sources of observed differences are discussed.

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