Atmospheric plasma sprayed thick thermal barrier coatings (TBCs), comprising of 1.5 mm
thickness yttria stabilized zirconia (YSZ) coating, have been developed for increasing
thermal protection of combustor applications. Different segmentation crack densities of the
YSZ coating were created by controlling the deposition conditions. It was found that the
substrate temperature played a dominant role in determining the segmentation crack
density. The density was found to increase with the increase of substrate temperature and …

Thermal barrier coatings (TBCs) with high strain tolerance are favorable for application in
hot gas sections of aircraft turbines. To improve the strain tolerance of atmospheric plasma
sprayed (APS) TBCs, 400μm–500μm thick coatings with very high segmentation crack
densities produced with fused and crushed yttria stabilized zirconia (YSZ) were developed.
Using a Triplex II plasma gun and an optimized spraying process, coatings with
segmentation crack densities up to 8.9 cracksmm− 1, and porosity values lower than 6 …