This paper describes the basic design and operation of a low-pressure plasma spraying (LPPS) system in use at Sandia National Laboratories. To demonstrate the versatility of the system, Sandia engineers, working in collaboration with the New Mexico Institute of Mining and Technology, produced thin (< 100 μm), dense yttria-stabilized zirconia coatings using three deposition mechanisms: liquid droplet, vapor, and mixed mode (vapor and droplet). Despite slight differences in equipment configuration, the work duplicates many of the results obtained in previous investigations, confirming the advantages of LPPS over other thin film deposition techniques.

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