Rare-earth zirconates with a pyrochlore structure have attracted great attention for potential application in thermal barrier coatings to further improve the performance and durability of gas turbines. In present work, the Sm2Zr2O7 coating was deposited by air plasma spraying technology, and its microstructure and phase composition were examined. The as-sprayed Sm2Zr2O7 coating exhibited anion-disordered while cation-ordered fluorite-type structure. Degree of ordering was considerable enhanced after high temperature aging, and transformed to ordered pyrochlore-type structure after thermal aging at temperatures above 1200 ºC. The typical lamellar structure for the as-sprayed Sm2Zr2O7 coating gradually decreased with increasing thermal aging temperature, which was caused by microcrack healing at high temperatures.

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