Build up of strain within thermal barrier coatings has been identified as one of the main reasons for coating failure. The large volume fraction of grain boundaries in nanostructured materials has been predicted to partially relieve the strain in a coating structure. In this study, the difference in morphological characteristics of regular PSZ (r-PSZ) particles and nano-agglomerate PSZ (n-PSZ) particles have been investigated to improve our understanding of the stresses and strains within a coating. The Triple Torch Plasma Reactor, a reduced pressure plasma spray system along with a pair of tungsten and molybdenum apertures was used to isolate spray particles from the plume to deposit splat sample. Cross sections of the splat samples were prepared. Image analysis techniques were used on scanning electron microscopy (SEM) images to characterize both the surface and the cross sectional features of the splat samples. Semi-molten structures were found to be the defining characteristic of the n-PSZ samples. Peak height distribution (PHD) was defined to quantify the distribution of the height of semi-molten structures. PHD was estimated for different samples and was found to track the changes in the morphological characteristics as a function of the deposition conditions.

Multilayer thermal barrier coatings are being investigated for high temperature applications by employing a strain accommodating interlayer. Plasma sprayed coatings of nanostructured feedstock have shown promise in this direction. Layers of nanostructured yttria stabilized zirconia (nano–YSZ) and conventional YSZ were deposited on mullite substrates using the triple torch plasma reactor (TTPR), and on NiCrAlY coated steel substrates using the Praxair SG-100 plasma torch. The coatings were heat treated and the microstructure evaluated. Heat treating the samples lead to the formation of larger pores with a significant proportion of partially molten particles. The porosity evolved from the partial sintering of the nano-agglomerates. Porosity change during the sintering process was measured and the microstructure observed using electron microscopy. The nanostructured coatings were compared to conventional YSZ coatings.

A two-wavelength particle imaging sensor has been developed to measure temperature and velocity of individual particles in most thermal spray devices. The sensor provides continuous updates to particle condition profiles, histograms and correlation’s. The software locates particle streaks, determines the intensity ratio and dimensions of each streak, and calculates the particle temperature and velocity. Many forms of advanced materials processing technologies, such as thermal spray, spray-forming and atomization have considerable need of process control sensor technology. These measurements provide the basis for application of the sensor to many of these processes. Particle temperature and velocity measurements of plasma-sprayed ceramic powder were obtained using the sensor. The average temperature varied from 2800 K to 3000 K as the current to the plasma was increased from 700 amps to 900 amps. The average velocity varied from 85 m/s to 99 m/s over the same range. These results compare favorably with similar measurements, reported in the literature. With its full-stream field of view, the vision-based particle sensor can be applied to control strategies for the purpose of providing stable particle temperatures and velocities over long duration plasma spray processes.