This study investigates the effect of deposition temperature and particle size on lanthanum strontium chromite (LSC) deposits produced by atmospheric plasma spraying. The results show that dense deposits with lamellar interface bonding can be achieved at temperatures above the critical bonding temperature and that particle size has a significant effect on chromium vaporization losses. The loss of chromium may be responsible for the low electrical conductivity of LSC deposits produced from small powders, which suggests that conductivity can be controlled with appropriate process adjustments.

This study assesses the potential of scandia-stabilized zirconia (ScSZ) produced by very low-pressure plasma spraying (VLPPS) for metal-supported solid oxide fuel cell (MS-SOFC) applications. To investigate the microstructure of ScSZ, coating samples were deposited at spraying distances of 150, 250, 350 mm. The fragile nature of coating cross-sections suggests that the typical lamellar structure of zirconia is replaced by a transgranular structure. Nonetheless, apparent porosity, ionic conductivity, open circuit voltage, and ohmic resistance measurements indicate that VLPPS is a viable method for producing MS-SOFCs.

This study shows how HVOF-sprayed NiAl coatings produced using chemical and electrochemical activation processes can serve as oxygen evolution electrodes in alkaline water electrolysis systems. Freestanding hierarchical NiAl structures produced without chemical binders exhibit electrocatalytic performance comparable to state-of-the-art noble catalysts characterized by very low overpotential and high current density without degradation.

Dense, nanostructured bismuth vanadate thin films were successfully deposited by aerosol deposition at room temperature. Aerosol deposition offers an alternative route for fabrication of photoactive metal oxide coatings as no binders or sintering processes are employed. A micron-sized bismuth vanadate powder was used to spray photoactive films (< 1 µm) on conductive fluor-doped tin oxide layers on glass and titanium substrates. The thin films are photocatalytically active under solar light due to the band gap energies of bismuth vanadate, and their nanosized structure increases surface area and catalytic activity. The coatings obtained were assessed based on microstructure, layer thickness, mechanical integrity, and photoelectrochemical activity.