This study investigates the influence of particle size and solid concentration in suspension on the microstructure of suspension plasma sprayed YSZ coatings. It also assesses the influence of plasma gases, plasma power, injector size, spray distance, and suspension feed rate. It is shown that suitable spray distance is necessary to achieve dense coatings with relatively coarse (0.6 μm) particles and that a columnar-like structure tends to be produced when fine (0.2 μm) particles are sprayed. The results also show that using Ar-He plasma and increasing total gas flow is an effective way to create dense vertically cracked (DVC) microstructure.

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