This study investigates the effect of high deposition rates and temperatures on the formation of vertical segmentation cracks in thermal barrier coatings. YSZ layers were deposited by atmospheric plasma spraying using different powder feed rates, raster speeds, and spraying distances. Coating cross-sections were examined, elastic properties were measured, and thermal conductivity was determined by laser flash testing. Coating structures with vertical and horizontal cracks are shown to be anelastic with high strain tolerance, even after heat treating at 1100 °C.

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