Different YSZ powders have been deposited by the high frequency pulse detonation (HFPD) thermal spray process leading to highly dense and hard coatings in comparison to standard APS zirconia layers. During this development, the gun configuration and the process parameters (gas flows, explosion frequency, spray distance and cinematic conditions) have been optimised to get the best deposition performance. In order to explore the potential of the HFPD system to process YSZ base materials, different type of commercial spray powders (agglomerated, fused & crushed, fully or partially stabilized compositions) and size distributions, have been investigated and the resulting coatings characterized. A qualitative comparison of the coating performance at elevated temperatures is presented and discussed. For this purpose, an experimental set-up was designed. Potential applications of these types of zirconia coatings in advanced thermal barrier coating systems, high temperature wear protection or ionic conductors (sensors and fuel cells) are discussed.

Ceramic oxides can be deposited by the High Frequency Pulse Detonation process leading to coatings with unique properties as result of simultaneous melting and high velocities of the sprayed particles. In this paper, several Al 2 O 3 based powders have been HFPD sprayed and the resulting coatings characterized. For this purpose, microstructural evaluation, XRD phase analysis and functional behavior (dielectric strength and wear resistance) have been tested.

A combination of pulsed combustion and advanced thermal spray technology has led to the development of the novel High Frequency Pulse Detonation (HFPD) spray technology by Aerostar Coatings. In the HFPD process, the flow of gaseous products from cycled explosions in the spray gun, is used to accelerate and heat the spray particles. This paper provides a fundamental description of this cyclical process, with the main differences to spray processes with stationary flow and also to traditional detonation spraying techniques in the center. Paper includes a German-language abstract.

The High Frequency Pulse Detonation (HFPD) thermal spray process represents a novel cost-effective alternative for the production of premium quality coatings. In this paper, the HFPD spray technique is characterized by very flexible capabilities which allow to deposit a wide range of materials according to different specifications. The spray parameters are carefully selected and adapted to the respective material or specification. The qualitative effect of each parameter on the coating properties and the reliability of the system are checked. Examples of different coatings are presented. Paper includes a German-language abstract.