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The integrity and properties of ceramic coatings produced by atmospheric plasma spraying are highly controlled by the splat morphology and splat interconnection. In this study, the influence of selected parameters (spray angle, surface velocity of the spray gun, and substrate temperature) on splat morphology and coating microstructure was investigated. A favorite set of spray gun parameters, of which their effects on splat morphology and coating microstructure have been verified by previous experiments, were used to conduct the experiments for the present work. It was found that depositing fully molten particles on a hot substrate increases the fraction of disk-like splats by about 60% at the expense of the fraction of irregular splats. Preheating the substrate also increases the pore count and level of coating porosity, while it does not influence the density of segmentation cracks. In contrast, the surface velocity of the spray gun does not affect the splat morphology while a slow speed decreases the coating porosity and plays a significant role in generating segmentation cracks. Shifting the spray angle by 15° distorts up to 20% of disk-like splats and slightly decreases the porosity level. However, changing the spray angle does not affect the generation of segmentation cracks.

journal of thermal spray technology

Influence of Direct Splat-Affecting Parameters on the Splat-Type Distribution, Porosity, and Density of Segmentation Cracks in Plasma-Sprayed YSZ Coatings