Understanding the Correlations Between the Formation of Columnar Structures and Suspension Properties for Suspension Plasma-Sprayed Thermal Barrier Coatings

Columnar-structured thermal barrier coatings deposited via the suspension plasma spray process have attracted significant attention due to their long thermal cycling life and high cost-effectiveness. In this work, the effects of suspension properties, including solvent type, viscosity, and particle size, on the formation of different coating microstructures were investigated via a comparative study. Two different kinds of solvents (water and ethanol) and particles of different sizes (D50 = 0.45 μm and 1.2 μm) were used to prepare suspensions for coating deposition, respectively. When using suspensions containing small-sized particles as feedstock, coatings deposited from the ethanol-based suspension showed columnar microstructures with inter-column crevices, while the water-based suspension resulted in cracked–columnar microstructures, showing a mixture of columns and cracks. When the large-sized particles were used to prepare the suspension, both the ethanol-based suspension and the water-based suspension resulted in homogeneous coating microstructures. The formation mechanism of different microstructures was investigated by modelling the diverted plasma jet and the in-flight particle movement during the impingement period. Particles smaller than 2 μm were strongly affected by the diverted plasma gas, showing obvious oblique impinging trajectories, while particles larger than 3 μm kept their original trajectories and impinged on the substrate orthogonally. The formation mechanism of different microstructures was elaborated by analyzing the impinging trajectories of particles transitioning from different suspensions.