In this paper the characteristics (microstructure, phase compositions) and electrical insulating properties of thermally sprayed alumina coatings produced by suspension-HVOF (S-HVOF) process and conventional HVOF spray method are compared. The electrical resistance (electrical resistivity) and dielectric strength were investigated using DC-electrical resistance measurements, electrochemical impedance spectroscopy (EIS) and dielectric breakdown test. The electrical resistance was determined at room temperature at different relative air humidity (RH) levels, from 6% RH up to 97% RH. Differences in the electrical insulating properties due to the different coating characteristics are discussed. The suspension-sprayed Al2O3 coatings showed better electrical resistance stability at high humidity levels (> 75% RH), which could be explained by a specific microstructure and retention of a higher content of α-Al2O3. Nonetheless, the values of dielectric breakdown voltage and dielectric strength recorded for suspension sprayed coatings were lower than those of HVOF coatings.

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