Abstract
In this study, zirconia coatings were fabricated by vacuum plasma spraying using hollow spherical and fused and crushed YSZ powders. Relationships between spray parameters and in-flight particle velocities and temperatures were investigated in real time and correlated with coating microstructure and density obtained under vacuum as well as atmospheric spraying conditions. The results indicate that plasma sprayed particles reach higher velocities under vacuum and slightly higher temperatures in atmospheric conditions. Powder morphology and structure play a major role in determining coating microstructure and porosity, especially in vacuum spraying. The fused and crushed powder yielded the densest coatings under the vacuum process conditions employed.
