The aim of this work, devoted to yttria stabilised zirconia (YSZ) thermal barrier coatings, is to produce by DC plasma spraying a single thick pass macro cracked orthogonally to the substrate. YSZ was plasma sprayed in air atmosphere on Hastelloy X substrates, with a NiCrAlY bond coat. A three-zone microstructure is observed, where lamellae and columns are present. The measurements of deposition stresses during spraying allow explaining the macrocrack formation.

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