High-purity globular yttria powders prepared by spray drying and sintering were deposited by air plasma spraying. The effect of powder properties and spraying parameters on coating structure and porosity was investigated. Yttria powders with grain size in the 20 to 50 μm range and loose density greater than 1.2 g/cm3 seemed to be the optimum selection for producing dense, high-quality coatings.

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