In this study, YSZ coatings are deposited by plasma spray-physical vapor deposition using a shroud to limit expansion of the plasma jet and increase its heating ability. Optical emission spectroscopy shows that the shroud significantly increases the evaporation of YSZ particles in the jet, resulting in coatings with a hybrid columnar structure. SEM examination of coating surfaces and cross-sections reveal micro and nanoscale features and, in each case, the mechanisms of formation are discussed.

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