DC plasma spraying has been widely recognized as a quick and economic way to produce all kinds of coatings (metals, alloys, and ceramics) for a variety of applications. There has been a growing interest in using radio frequency (RF) plasmas. Studies have been reported on characterization of plasma-sprayed coatings by TEM, including thermal barrier coatings, alumina coatings, and Ni-Al coatings. There are, however, no detailed studies reported on microstructural comparisons of coatings prepared by RF and DC plasma spraying. In this paper, XRD, SEM, TEM, polarizing OM, four-point bending fracture, and molten particle impact behavior are used to clarify microstructural differences between the RF- and DC-coatings. The results showed that the microstructures were much different for both cases, especially in the interfacial region between the coatings and the substrates. Paper includes a German-language abstract.

A new plasma spray process was developed for the rapid deposition of very dense electrolyte layers for solid oxide fuel cells (SOFCs). The dense yttria-stabilized zirconia (YSZ) film was prepared by a center-injection low pressure plasma spraying (CI-VPS) process on various substrates in a triple-torch reactor. For deposition on porous substrates, an intermediate layer was applied using conventional atmospheric plasma spraying (APS) to close the large pores in the substrate. The films were characterized by XRD, SEM, and EMPA. The porosity of the film was analyzed by computerized image analysis of the micrographs. The film was also fractured by four-point bending to characterize the nature of bonding of layer-to-layer and within the deposit. The film analysis showed that YSZ layers with porosities of 0.3 % could be obtained at very high deposition rates with the CI-VPS process, with a very good functional performance of the layer as an electrolyte. Building of a complete SOFC by successive deposition of an atmospheric pressure sprayed porous cermet film, the dense YSZ electrolyte layer, and a porous perovskite film is discussed.

The quality of a plasma sprayed coating is influenced by the plasma jet stability; entrainment of cold air through large scale turbulence can lead to variations in particle heating and trajectories resulting in increased unmelt densities, reduced deposition efficiencies, and oxidation of metal particles. The jet instabilities are in part caused by the swirl flow of the plasma gas. With two modifications to an atmospheric pressure plasma spray torch, we have investigated the influence of reduced swirl flow on jet stability, particle trajectories, and coating quality. The modifications are (1) addition of a shroud consisting of a porous ring surrounding the anode nozzle while simultaneously injecting part of the shroud gas inside the nozzle with a swirl component in the direction opposing the plasma gas vortex, and (2) an injector ring with which part of the plasma gas is injected radially and part tangentially producing reduced vortex flow for the same plasma gas flow rate. Jet stability and particle trajectories are determined using a LaserStrobe system combined with image analysis, and coatings have been evaluated by determining porosity and unmelt density. Results indicate that deposition efficiency is most affected by reduced vortex flow, while the shroud addition reduces unmelt density and porosity.