In this study, a cascaded plasma gun is used to make YSZ coated coupons while measuring particle temperatures and velocities. Deposition efficiency and abrasion resistance are compared for coatings produced under low-temperature, high-velocity and high-temperature, low-velocity spraying conditions. Formations of shell-shaped splats were found on coating surfaces sprayed at high temperature and low velocity. The shell-shaped splats and resulting coating morphology likely contributed to the lower abrasion resistance of the coating. Other correlations between coating morphology, properties, and spraying parameters are also reported.

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