A number of plasma-sprayed yttria-stabilized zirconia coatings were prepared representing a combination of significantly different starting powders and different plasma torch designs. The coatings had densities in the range 85%-91% of the theoretical. Coating hardness, particle erosion resistance and cohesive strength were proportional to density. The thermal fatigue resistance of zirconia coatings, 1.3 mm (0.05 in) thick, increased with increasing density, but their thermal insulation value was inversely proportional to density. In general, the coatings exhibited a number of properties related to density without separate regard to process. © 1990.
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