Fabrication and Characterization of Amorphous Alumina-Yttria-Stabilized Zirconia Coatings by Air Plasma Spraying

Xuemei Song, Tomi Suhonen, Tommi Varis, Liping Huang, Xuebin Zheng, Yi Zeng (Corresponding Author)

    Research output: Contribution to journalArticleScientificpeer-review

    29 Citations (Scopus)


    Almost fully amorphous coatings of near-eutectic alumina-yttria-stabilized zirconia (Al2O3-YSZ) were prepared by air plasma spraying using Al2O3 and 8 mol.% YSZ crystalline-mixed powders. The coatings consist of mostly an amorphous phase with a small amount of nanocrystals. Various characterization techniques were used to understand coating formation and the origins of the different phases within the coatings. The formation of the mostly amorphous structure is attributed to the high glass-forming ability of Al2O3-YSZ and the appropriate plasma spraying conditions. A small number of nanocrystals are produced during crystallization of the incoming molten droplets or by recrystallization of the solidified splats by accumulated heat. Scanning electron microscopy shows that the coatings have a dense, layered structure with low porosity, and bright-field transmission electron microscopy images indicate sharp interface rather than grit-blasted wavy surface between splats and substrates in the coatings. The as-sprayed amorphous coatings crystallized at around 920 °C and micro-hardness of the as-sprayed amorphous coatings was 8.12 GPa.
    Original languageEnglish
    Pages (from-to)1302-1311
    Number of pages9
    JournalJournal of Thermal Spray Technology
    Issue number8
    Publication statusPublished - 2014
    MoE publication typeA1 Journal article-refereed


    • alumina-yttria-stabilized zirconia
    • amorphous phases
    • atmospheric plasma spraying
    • microhardness
    • nanocrystals
    • thermal stability
    • ProperPart
    • ProperTune


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