In this study, yttria films with high thermal shock resistance were synthesized from a metal-EDTA complex by means of combustion flame spraying. A rotating stage and various cooling agents were used to control substrate temperature during deposition. Although thermally extreme environments were employed during synthesis, the obtained films showed only a few cracks and some minor peeling in their microstructures. In the case of a Y 2 O 3 film synthesized using substrate rotation and water atomization, the porosity was found to be 22.8% and the temperature of the film immediately after deposition was 453 °C, owing to a high heat of evaporation in the cooling water.

Development of thermal spraying of quasicrystalline coatings is connected with development of new powders for produced from alloyed quasicrystalline alloys. Powders of AlCuFe alloyed by Cr and Sc were produced by high – pressure water atomization of melt. Phase composition, microstructure, morphology, flowability of the powders were investigated. Resistance of powders to oxidation in air was studied using thermography. It was determined that doping of AlCuFe – alloy by 0,265 and 0,440 at.% Sc and by 8 at.% Cr significantly increases in them content of quasicrystalline phases. Annealing of AlCuFeCr at 550°C leads to transformation quasicrystalline phase into crystalline approximant of decagonal quasicrystalline phase.

The excellent wear-resistant performance of cast iron coatings considerably depends on the formation of graphite structure with an inherent self-lubricating property. In the present study, two types of cast iron powders produced by gas- (GA) and water-atomization (WA) were deposited on an aluminium alloy substrate by atmospheric DC plasma spraying. WA powders are generally characterized by high oxygen content, irregular appearance and inexpensiveness compared with those of GA powders. Although alloying elements of silicon and aluminium work as a strong graphitizer and anti-oxidizer, graphite structures are not recognized in coatings sprayed with as-atomized high silicon and aluminium powders. Therefore, either pre-annealing of powders or post-annealing of coatings is required to achieve cast iron coatings containing graphite structure. A marked decrease in graphite occurs to the coatings with pre-annealed GA powder, since there exists precipitated graphite mainly on a GA powder surface. A short period of post-annealing is also valuable for graphitization. The weak oxide layers are observed in coating cross-sections with GA and WA powder, however, their oxidized levels are much lower than those with bearing steel powder containing low silicon and aluminium. Hence, graphitized cast iron coatings sprayed with inexpensive WA powder exhibit a splendid anti-wear performance.