In this paper, yttria-stabilized zirconia (YSZ) coatings were prepared by plasma spraying of ready-to-spray suspensions provided by three different manufacturers. High-enthalpy hybrid water-argon plasma torch WSPH 500 was successfully used for deposition of coatings with porous and columnar microstructure consisting of tetragonal non-transformable phase. Sensitivity of the deposition process to variation of deposition conditions was also evaluated by the change of suspension injection point position. Slight differences in the microstructures of the deposited coatings (in particular character of porosity and mutual bonding of the microsplats) were reflected in slight but measurable differences in hardness and wear resistance of the coatings indicating changes in the coating cohesion. Tensile adhesion/cohesion strength of the coatings was found to be in the range of 9 to 15 MPa. High coating porosity desirable for low thermal conductivity combined with high suspension feed rate (from about 100 to 120 ml/min in this study) makes the WSP-H coatings promising for further development for example in thermal barrier coatings applications.

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