Optimization of suspension formulations for YSZ Suspension Plasma Spraying (SPS)

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PhD student Jade Orlandi, jade.orlandi@unilim.fr; Lucille Roumet, lucille.roumet@unilim.fr; Laurent Joly Vuillemin, laurent.joly-vuillemin@imerys.com; Assistant professor Anne Aimable, anne.aimable@unilim.fr; Professor Alan Keromnes, alan.keromnes@unilim.fr;

https://doi.org/10.53192/ITSC2026576

CYSZ thermal barrier coatings, elaborated through suspension plasma spraying (SPS), are widely used in industry. This process presents many advantages thanks to the versatility of its microstructure and its ability to process complex parts in large quantities. Therefore, numerous studies have been carried out to control coating microstructure, either by optimizing spraying parameters, or through the suspension characteristics, especially powder particle size and adjuvants used (modification of viscosity, suspension surface tension, etc.) [1,2]. This implies a precise control of the thermokinetic behavior of the particles in the plasma plume, providing deeper insight into the factors that govern suspension formulation — a critical aspect for ensuring industrial reproducibility and for defining the intrinsic properties of the resulting deposit [3].
The objective of this study is to optimize the formulation of suspensions to ensure a better industrial reproducibility which implies stable formulation. Thus, a stability threshold for the SPS process was defined using turbidimetry analysis to identify any destabilization. The influence of dispersants and ceramic powders characteristics was investigated during the projection (on-line measurements), as they considerably impact spraying capability and thus the final microstructure and coatings.  Resulting coatings and in-flight collected particle have been characterized by scanning electron microscopy and x-ray diffraction.

References:
[1] Tarasi F, Alebrahim E, Dolatabadi A, Moreau C. A Comparative Study of YSZ Suspensions and Coatings. Coatings, March 2019, Volume 9.
[2] Blas F, Ansart F, Lours P, Bonino JP, Duluard S, et al. Processing thermal barrier coatings via sol-gel route: crack network control and durability. Surface and Coatings Technology, 2018, Volume 334, p.71-77.
[3] Chergui A, Lebot C, Rat V et al. Physical mechanisms in plasma processing. Journal of Thermal Spray Technology, 2025, Volume 34, p.735-752.

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Erscheinungsdatum

March 2026

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