The aim of this study is to better understand the formation of nonbonded splat-to-splat interfaces in thermally sprayed ceramic coatings. To that end, the surfaces between splats in plasma-sprayed La0.5Sr0.5CoO3 (LSCO) coatings were examined and compared to free splat surfaces. The results show that free splat surfaces are relatively smooth, while adjacent surfaces at intersplat interfaces are quite rough. The observation implies that nonbonded splat-to-splat interfaces were never bonded, having fractured due to interface shear stress generated during splat cooling.

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