In this work two different thermal spray techniques were used to deposit La0.9Sr0.1CrO3 interconnect material: high velocity oxy-fuel (HVOF) using a modified nozzle and atmospheric plasma spray (APS). Two different APS torches were employed: A commercial torch that uses Ar/H2 as plasma forming gases and a new torch design that uses CO2 gas mixtures. A substitute powder with similar physical properties to La0.9Sr0.1CrO3 was employed for the development and optimization of the process parameters to achieve the highest density before the deposition of the La0.9Sr0.1CrO3 on zirconium oxide substrates. The microstructures observed by scanning electron microscopy (SEM) and the phase composition of the coatings obtained from X-ray diffraction analysis are correlated to the spraying characteristics of the different techniques employed. The electrical resistivity of the as-sprayed coatings is discussed in terms of microstructure features and the phase composition. Post-deposition heat treatments were studied in order to reduce the electrical resistivity.

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