Fabrication and Characteristic of ZrO2-8%Y2O3 Powder for Plasma Spray Coating Manufactured by Mechanical Mixing Method

Thermal barrier coatings(TBCs) are being applied in many industrial fields such as thermal power generation, aviation and seasonal fields. ZrO2-Y2O3(8 %) thermal spray coating powders are commercially used as thermal-barrier coating materials to protect against oxidation and corrosion of heat-resistant alloys at elevated temperatures. Currently, ZrO2-Y2O3(8 %) thermal-spray powder is made using the industrial co-precipitation process, which is very complex and requires a lot of time. In this study, orthorhombic ZrO2 and Y2O3 powders were fabricated by mechanical mixing, which is more economical than the co-precipitation process. A tetragonal, yttria-stabilized zirconia(YSZ) coating-layer was produced by plasma spraying, using orthorhombic ZrO2-Y2O3(8 %) powder. Our experimental results indicate that ZrO2-Y2O3(8 %) mixed powder can be used economically in industry because it is no longer necessary to make this powder by liquid and gas-phase methods.