In this study, solution precursor plasma spraying is used to produce LaAlO3 perovskite topcoats for thermal barrier coating systems. LaAlO3 solution precursors were prepared by in situ polymerization and were deposited under different conditions in order to determine the effect of spraying parameters on process yield, deposition rate, microstructure, and hardness. Preliminary results with deposition rates of 5-20 μm/pass and process yields in the range of 35-60% are presented. It is shown that low precursor solution feed rate, high plasma power, and medium atomization gas flow rate result in acceptable coating microstructure, although further optimization is needed to achieve adequate hardness.

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