A simplified ID model has been developed to calculate the temperature time history of alumina layering splats. The splats were obtained by plasma spraying alumina fused and crushed particles (- 45 + 22 µm). The model has shown that for more than 160-200 µm layered splats the solidification time is over 7-10 µs, When spraying thin passes (ep < 15 µm) each splat cools down to substrate preheating temperature before next splat impacts. On the contrary for thick passes (ep = 60 or 180 µm), after depositing a certain thickness (between 160 and 200 µm) depending on spraying conditions, the temperature of the splats never drops below 800-900 K (mean splat temperature). In this case nucleation occurs after flattening is completed. Such conditions allow a columnar growth through the layered splats of each pass and successive passes. The study of the corresponding stresses (quenching σq and expansion mismatch) generated when spraying alumina on XC38 sheet was measured by following continuously the bending of a beam. The comparison of the measurements with the results of a ID model developed by Tsui and Clyne has allowed to calculate the coating Young's modulus Ed and the residual stresses difference at the interface. For thin coatings σq and Ed increase with preheating temperature. For thick coatings the values of Ed and σq are lower than the highest ones of thin coatings. This is probably due to stress relaxation by cracks propagation, the quenching and expansion mismatch stresses increasing with the increasing mean splat temperature.

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