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A novel Al2O3-GdAlO3 (GAP) amorphous ceramic coating was in situ prepared via atmospheric plasma spraying (APS). The Al2O3/Gd2O3 sprayable powders possessed excellent sphericity and fluidity after heat treatment at 1173 K without solid-phase reaction, which indicated that the Al2O3-GAP coating deposition process was significantly simplified. The Al2O3-GAP amorphous coating showed high glass transition temperature (1155.1 K), initial crystallization temperature (1179.2 K), local activation energy (847.6 kJ/mol) and nucleation resistance (88.3). Compared with almost all amorphous materials, the Al2O3-GAP amorphous coating possessed greater crystallization activation energy, which was conducive to its high-temperature microstructure stability. Furthermore, the hardness and elastic modulus of Al2O3-GAP coating fluctuated with a tiny range when increasing the nanoindentation depth from 500 nm to 2000 nm, which exhibited excellent uniformity of microstructure and mechanical performance of the coating. Therefore, the results showed that the Al2O3-GAP amorphous coating had a better potential for large-scale engineering application under harsh service conditions.

In Situ Deposition of Amorphous Al2O3-GAP Ceramic Coating with Excellent Microstructure Stability and Uniformity via Atmospheric Plasma Spraying