Axial Plasma Spraying Slurry Coatings for Various Emerging Applications

Slurry plasma spraying is gaining greater interest in commercial applications where thin and dense coatings are desired. Based on previous development on slurry coatings at Mettech, the current paper is aimed at overcoming the complexities of the process and gaining a better understanding of the coating mechanisms. With the axial injection plasma system and automatic slurry feed system, the effect of powders, slurries, atomization, plasma parameters and coating process on coating quality were explored.  The coating microstructure and properties were tailored for emerging applications such solid oxide fuel cells , new thermal barrier coatings applications, and next generation environmental barrier coatings.