Suspension plasma spraying is a process which enables production of finely grained nanometric or submicrometric coatings. The suspensions were formulated with the use of fine powder of ceramic particles of yttria stabilized zirconia in water with alcohol. The present paper focuses on the theoretical analysis of the formation process of sintering of fine solids impacting the growing coating’s surface. The heat flux input to the coatings was estimated and their surface temperature at spraying was measured. The theoretical analysis of sintering during the coating’s growth was carried out. The different models of sintering were analyzed and adapted to the suspension plasma spraying conditions. The model of surface diffusion was found to be the most appropriate to describe the sintering during suspension plasma spraying. The formation of the necks having the relative size equal to 10 % of the particle diameter was found to be possible during the coatings deposition.

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