In this study, the induction plasma spheroidization (IPS) technique was adopted to improve the microstructure and properties of the traditional agglomerated ZrO2-7wt%Y2O3 (YSZ) powders used in thermal barrier coating (TBC) applications. Compared with agglomerated YSZ powders, IPS-treated powder has a more desirable microstructure, and the overall performance of the spray powders for TBC preparation is significantly improved. Specifically, IPS-treated powder has a dense, solid, defect-free, and chemically uniform microstructure, and its apparent density, flowability, and powder strength are significantly improved, which is believed to substantially enhance the coating performance when prepared with this IPS-treated powder.
Keywords: induction plasma spheroidization (IPS); powder performance improvement; thermal barrier coatings (TBCs); yttria-stabilized zirconia (YSZ) powders.