Manufacturing of MnCo 2 O 4 spinel coatings by solution precursor plasma spraying (SPPS) was studied in order to produce thin ceramic coating on a ferritic stainless steel interconnect for SOFC’s. The main purpose to use MnCo 2 O 4 coating in SOFC devices is to prevent the migration of harmful CrO 3 and Cr 2 (OH) 2 compounds to the triple phase barriers (TPB) of the cathode. In this study Mn(NO 3 ) 2 •4H 2 O and Co(NO 3 ) 2 •6H 2 O were diluted to deionized water and mixture of deionized water and ethanol at 3 M mixture rate. The solutions were sprayed on 0.5 mm thick Crofer 22 APU substrate by Sulzer Metco F4-MB plasma gun with a modified solution feeder. Microstructural characterizations for the as-sprayed coatings were done by using a field-emission scanning electron microscopy (FESEM) with SE-mode. Elemental analyses were done with energy dispersive spectroscopy (EDS) and an X-ray diffraction (XRD) was used for crystallographic studies. The coating with full equivalence of the crystallographic structure of MnCo 2 O 4 spinel was sprayed using argon-helium plasma and water based solution. Plasma gas with hydrogen as a secondary or ternary gas and ethanol based solutions caused the formation of the mixed phases of CoO and MnCo 2 O 4 . Although the microstructures of sprayed coatings were still quite porous, the influence of relevant gun and solution parameters were found in order to improve coating denseness in further studies.

Thermal spraying of pure SiC is difficult due to decomposition issues at elevated temperatures. However, the development of suspension plasma spray opens a new path to investigate the deposition of this material since the liquid carrier can hinder this phenomenon. The present work investigates a new route for producing SiC submicron structured coating by suspension plasma spraying (SPS). Classical SiC manufacturing routes using suspension (i.e: spray drying, tape casting) are studied regarding their feasibility to be used on suspension plasma spraying. Aqueous-based suspensions containing 10 wt.% SiC powder (0.60 µm) along with sintering additives are dispersed and stabilized. Both suspensions are sprayed on martensitic stainless steel substrate (AISI 440C) to achieve finely structured and dense coatings. Digital image analysis, X-ray diffraction and scanning electron microscopy are utilized to characterize the coating microstructures. Their dependency on suspension characteristics and spray operation parameters are discussed with respect to the final coating performance.

Suspension plasma spraying (SPS) is regarded as a promising way to produce new coating structures with improved properties. In this study, SPS was studied as a possible manufacturing process for producing thin MnCo 2 O 4 spinel coatings for used as protective coatings in metallic interconnector plates of SOFC’s. Suspension of nanosized MnCo 2 O 4 powder and ethanol was thermally sprayed by using an F4-MB plasma gun with radial suspension feeding. The influence of spraying parameters, such as plasma gas composition, total gas flow, current and spraying distance for coating architecture was studied by using field-emission scanning electron microscopy (FESEM) and X-ray diffraction method (XRD). Spraying parameters had a strong influence on the coating structure and composition. Coating with the most homogenous structure were formed when sprayed with the low energy spraying parameters whereas high energy parameters resulted in formation of a columnar microstructure containing larger cobalt rich areas.

Manganese cobalt oxide spinel doped with Fe 2 O 3 was studied as protective coatings on alloyed metallic interconnect plates for solid oxide fuel cell applications. Chromium alloying causes problems at high operation temperatures in oxidising conditions, on the cathode side of the fuel cell. The formed chromium oxide layer tends to form a thin layer of chromium trioxide or chromium hydroxide which evaporates at certain oxygen partial pressures more easily than chromium oxide and thus poisons the cathodes active area causing the degradation of the solid oxide fuel cell. Thermal spraying is regarded as a promising way to produce dense and protective layers on top of ferritic steels to lower the degradation processes and extend the lifetime of the SOFC device. In the present work, the ceramic Co-Mn-oxide spinel coatings were produced by using the atmospheric plasma spray process. The structures and compositions of the coatings were characterized using scanning electron microscopy (SEM), X-ray diffraction (XRD) was used to study the phase structure in as-sprayed and heat treated coatings and mechanical properties were examined by using micro hardness tester. Coatings with low thickness and micro structurally dense structures were produced by using optimal deposition conditions.