The objective of this work is to analyze the thermal conductivity of suspension plasma sprayed thermal barrier coatings using experimental techniques and finite element modeling. The results indicate that the scale of the porosity in the coating has a significant influence on thermal conductivity. Smaller grains, higher overall porosity content, and lower columnar density correspond to lower thermal conductivity. It is shown that FEA can be a powerful tool to predict the thermal conductivity of SPS thermal barrier coatings.

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