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Yb2O3-Gd2O3-Y2O3 co-doped ZrO2 (YGYZ) is considered to be a promising material in thermal barrier coating (TBC) applications. In this study, 2Yb2O3-2Gd2O3-6Y2O3-90ZrO2 (mol.%) (10YGYZ) feedstock candidates for air plasma spraying (APS) were prepared by calcination of agglomerated powders at 1100, 1200, 1300, 1400, and 1500 °C for 3 h, respectively. Incomplete solid solution was observed in calcined powders at 1100, 1200 and 1300 °C, and the 1500 °C calcined powder exhibited poor flowability due to intense sintering effect. The 1400 °C calcined powders were eventually determined to be the optimized feedstock for proper phase structure (cubic phase), great flowability, suitable apparent density and particle size distribution, etc. 10YGYZ TBCs with the optimized feedstock were prepared by APS, exhibiting pure c phase and good chemical uniformity. Controllable preparation of coatings with different porosity (i.e., 7%–9% and 12%–14%) was realized by stand-off distance adjustment.

Optimization of Yb2O3-Gd2O3-Y2O3 Co-Doped ZrO2 Agglomerated and Calcined Powders for Air Plasma Spraying